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Part 1

1. Screen 4 This screen shows the status of the overcurrent relay the discharge thermal protector and the compressor thermal protector of circuit 1 Line n Display Description Possible settings 1 DIGITALINPUTS screen title 2 SVERCURRENT overcurrent relay circuit 1 BA NOT DA 3 BISCH TH PR 1 discharge thermal protector circuit 1 BA NOT DA 4 COMPR TH PR 1 compressor thermal protector circuit 1 4 NOT DA You can find more information in Overview of Inputs and Outputs of EUWA 40 60K X on page 3 4 Screen 5 This screen shows the status of the overcurrent relay the discharge thermal protector and the compressor thermal protector of circuit 2 Line n Display Description Possible settings 1 DIGITAL INPUTS screen title 2 OVERCURRENTE overcurrent relay circuit 2 O4 NOT OR 3 DISEH TH PR e discharge thermal protector circuit 2 BK NOT DA 4 COMPR TH PR e compressor thermal protector circuit 2 B4 NOT DA You can find more information in Overview of Inputs and Outputs of EUWA 80 120K X on page 3 5 Screen 6 This screen shows the status of the remote dual set point switch and the remote start stop Line n Display Description Possible settings 1 DIGITAL INPUTS screen title 2 DUAL SETPOINT dual set point switch SETP 1 2 3 REM START STOP remote start stop YES NO You can find more information in Ove
2. 2 7 Read out Menu Operational Using this menu you can read the actual operational information such as the cooling set points the information inlet and outlet water temperature the circuits status etc This menu provides 6 screens Screen 1 This screen shows information about the operation mode the set points and the temperatures Line n Display Description 1 MANUAL MODE manual control mode INLSETP I C automatic control mode inlet water setpoint 1 or 2 GUTILSETP 1 2 automatic control mode outlet water setpoint 1 or 2 2 INLET WATER actual inlet water temperature 3 OUTLET WATER actual outlet water temperature 4 THERMOSTAT STEP actual thermostat step Screen 2 This screen shows information about the status of the circuits Line n Display Description 1 UNIT STATUS screen title 2 3 Ci Ce circuit 1 circuit 2 40 status information circuit ON this percentage refers to the activated capacity value of the circuit BYPASS MODE the internal controller is being bypassed and the unit is controlled by an external controller 7 SAFETY ACTIVE one of the circuit safety devices is activated LL O DISABLE the circuit is disabled by a remote contact only for E EUWA 80 120K X TIMERS BUSY one of the software timers is counting refer to page 2 30 CAN START UP the circuit is ready to start up when extra cooling load is requested 4 UNT CAPACITY the percentage refers t
3. Load defaults When you have entered the factory menu proceed as follows Step Action Result 1 Scroll downwards using _ to go to the next screen 2 Press Y 3 times The cursor is blinking on Non the load defaults line 3 Scroll downwards using _ to change into 4 4 Press Y When 3 becomes again all the default values are loaded into the new PCB 5 Scroll upwards using _ to go to the first screen You can start initialization 6 Press Y Settings Follow the screens on the next page to insert the settings of the former PCB 3 26 Part 3 Troubleshooting ESIE98 03 Troubleshooting Screen 1 This screen shows the information about the unit type Line n Display Description Default setting To change the setting 1 UNIT TIPE chiller type EUA Bu 1 circuit 1 Use _ to select the correct type EUIABD 2 circuits 2 Press 2 MANUFACT NR manufacturing number 808008 1 Use amp and 4 to change the digits 2 Press O 3 REFRIGERANT refrigerant type R 134A 1 Use _ to select the correct refrigerant 2 Press e To go to the next screen scroll downward using _ and press once Screen 2 This screen shows the information about the protection settings Line n Display Description Default setting To change the setting 1 PUN GUTL WATER minim
4. J1 B7 J1 244 high pressure 41 B8 J1 24V low pressure Front switch box side DAIKIN EUROPE NY haso 1TW51136 1 Part 1 System Outline 1 41 ESIE98 03 Wiring Layout Wiring diagram EUWA 80 120K X Power Supply 3 50Hz 400V Power Supply 1 50Hz 230V NOTES TO GO THROUGH BEFORE STARTING THE UNIT 1 eLt1Z13 main terminals e 1 50 terminals on main rail terminals for fans terminais on fol rail main terminals in compressor switchbox ther terminals in compressor switshbox 3 aire number 13 13 we DIGITAL INPUTS low pressure switch 1 high pressure switch 1 disch th prat 1 compr motor tn prot 1 IBA 107 DCM2 flowswitch JBA 008402 controller bypass 433A ID94DCM2 dual setpoint JBA ID10 IDCM1 remote start stop J38 ID10 DCN 21A 1D11 IDYIR emergency stop J218 IDA 421A 1012 1012 2218 1012 1012R S input terminals tor fering
5. PCB page 1 32 and page 1 34 power supply covers page 3 13 S3T bimetal page 2 14 schroeder valve page 3 28 sight glass page 1 28 star delta configuration page 3 13 unloader valves page 1 28 A 2 Appendix A Photo parts ESIE98 03 Introduction Drawings table Appendix B Drawings In order to find quickly the drawings inserted in this manual appendix B offers a list with all the drawings The following table shows the page and description of all the drawings Call outs See page coefficient of performance R 134a versus R 12 page 4 14 compression ratio R 134a versus R 12 page 4 14 compressor discharge temperature R 134a versus R 12 page 4 14 Fans location page 2 9 Fan control procedure page 2 8 Front panel of the digital controller page 2 18 Functional diagram EUWA 40 60K page 1 22 Functional diagram EUWA 80 120K page 1 23 Functional diagram EUWA 40 60KX page 1 24 Functional diagram EUWA 80 120KX page 1 25 Heatertape procedure page 2 15 Inlet water temperature control page 2 6 and page 2 28 Input route page 3 18 Installation outline page 3 18 Location in switchbox EUWA 40 60K X page 1 44 Location in switchbox EUWA 80 120K X page 1 45 Location in wiring diagram EUWA 40 60K X page 1 44 Location in wiring diagram EUWA 40 60K X page 1 45 Main board EUWA 40 120K X page 1 34 Ope
6. SIMP pian B2P BS A R3T y x Y a x x E STOPVALVE y O O mic gt OPTIONAL lt p Mac O B pt Olo gt F amp mt o Op s LL suction Ra l gt p STOPVALVE m LA OPTIONAL dla E Y mm m Y SAFETY VALVES SAFETY VALVES AT 28 BAR gt 14 AT 28 BAR O Y XIS Xx l r vids R e O a oes Y24S S4T Condenser Condenser BST eee mmm mmm KPN CHECKVAIVE lt amp FLARE CONN SCREW CONN FLANGE CONN X PINCHED PIPE SPINNED PIPE Part 1 System Outline 1 23 Piping Layout ESIE98 03 Functional diagram The figure below displays the functional diagram of the refrigeration circuit of the chiller types EUWA 40 60KX EUWA 40 60KX 0 Y12S O v138 BIP sip 14H E
7. Steps lead Steps lag Capacity Steps lead Steps lag Capacity compressor 1 compressor 2 compressor 1 compressor 2 0 0 0 0 0 0 40 0 25 40 0 25 70 0 38 70 0 38 40 40 50 100 0 50 70 40 63 70 40 63 70 70 76 100 40 76 100 70 88 100 70 88 100 100 100 100 100 100 Part 2 Functional Description 2 13 Functional Control ESIE98 03 1 8 Discharge Temperature Protector Protector The discharge temperature protectors S3T and S4T only for EUWA 80 120K X are bimetal devices which are placed on the discharge pipe of the compressor Conditions The discharge temperature protector will activate when m the discharge temperature rises above 135 C The reset is done when m the discharge temperature decreases below 115 C Illustration The following photo shows the position of the sensor S3T S3T bimetal 2 14 Part 2 Functional Description ESIE98 03 Functional Control 1 9 Heatertape optional Introduction This heatertape can be installed to prevent freezing up of the evaporator The evaporator heatertape needs a separate 220V field supply A During the winter never switch off the field supply of the heatertape if you want to activate it Heatertape The following procedure explains the procedure of the heatertape procedure total cap 0 and Tamb lt MOW Heatertape ON Heatertape OFF Tamb gt MOW 3K
8. Part 3 Troubleshooting ESIE98 03 Checking the Inputs and Outputs Table 1 In the following table you will find the temperature resistance values of the controller sensors R3T R4T and R5T sempre Resistor value Ait nad Resistor value Tempera Resistor value maximum standard minimum maximum standard minimum maximum standard minimum C kQ kQ kQ c kQ kQ kQ c kQ kQ kQ 50 344 40 329 20 314 70 1 26 64 26 13 25 62 56 3 49 3 42 3 35 49 324 70 310 70 297 20 2 25 51 25 03 24 55 57 3 39 3 31 3 24 48 306 40 293 30 280 70 3 24 24 23 99 23 54 58 3 28 3 21 3 14 47 289 20 277 00 265 30 4 23 42 22 99 22 57 59 3 18 3 11 3 04 46 273 20 261 80 250 60 5 22 45 22 05 21 66 60 3 09 3 02 2 95 45 258 10 247 50 237 20 6 21 52 21 15 20 78 61 2 99 2 92 2 86 44 244 00 234 10 224 60 7 20 64 20 29 19 95 62 2 90 2 83 2 77 43 230 80 221 60 212 70 8 19 80 19 40 19 15 63 2 81 2 75 2 69 42 218 50 209 80 201 50 9 19 00 18 70 18 40 64 2 73 2 66 2 60 41 206 80 198 70 191 00 10 18 24 17 96 17 67 65 2 65 2 58 2 52 40 195 90 188 40 181 10 11 17 51 17 24 16 97 66 2 57 2 51 2 45 39 185 40 178 30 171 59 12 16 80 16 55 16 31 67 2 49 2 43 2 37 38 175 5 168 90 162 00 13 16 13 15 90 15 87 68 2 42 2 36 2 30 37 166 20 160 10 154 10 14 15 50 15 28
9. 1 28 Part 1 System Outline ESIE98 03 Piping Layout 12 40 70 ambient thermistor outlet water connection outlet water temperature sensor Part 1 System Outline 1 29 Piping Layout ESIE98 03 1 30 Part 1 System Outline ESIE98 03 Wiring Layout 3 Wiring Layout 3 1 What Is in This Chapter Introduction The purpose of this chapter is to guide you through the switch box and the wiring diagrams Therefore we have used schematic drawings which indicate and locate the necessary information on both the switch box and the wiring diagram Overview This chapter covers the following topics Topic See page 3 2 Switch box Layout page 1 32 3 3 Main PCB Layout page 1 34 3 4 Wiring Diagrams page 1 40 3 5 Field Wiring page 1 43 Part 1 System Outline 1 31 Wiring Layout ESIE98 03 3 2 Switch box Layout Location The chiller types EUWA 40 120K X have only one switch box m For the models EUWA 40 60K X the switch box is located in the front m For the models EUWA 80 120K X the switch box is located at the side Photo switch box The following picture shows a the main components of the switch box of EUWA 80 120K X controller PCB emergency stop fan contactors contactors for star delta 1 32 Part 1 System Outline ESIE98 03 Wiring Layout Switch box The following figure s
10. General overview The following table shows a general view of freeze up temperatures in case of protection and prevention Minimum outlet water FP Set Freeze up protection FP Solution Glycol weight M O W Standard 4 GC 2 5 C 0 0 ZH 5 C 6 5 C 16 C 30 ZL 10 C 11 5 C 22 C 40 with FP Set DDC software of the freeze point equal to M O W with FP Solution actual freeze point value of the water glycol solution Part 2 Functional Description 2 15 Functional Control ESIE98 03 1 10 Head Pressure Setback Introduction The following table explains wen a high pressure HP setback can occur If and then HP R 134a gt 15 5 bar 59 C compressor step 100 compressor step becomes 70 HP R 22 gt 23 5 bar 59 C compressor step 100 compressor step becomes 70 Reset Once activated the head pressure setback will stop after 3 minutes 2 16 Part 2 Functional Description ESIE98 03 The Digital Controller 2 The Digital Controller 2 1 What Is in This Chapter Introduction In this chapter you will learn to work with the controller for the chiller types EUWA 40 120K X Overview This chapter covers the following topics Topic See page 2 2 The Digital Controller page 2 18 2 3 Start Stop and Temperature Setting page 2 19 2 4 What Happens in
11. the optional wiring for pump start stop is installed Oo a RA oO NY the optional wiring for remote control is installed Make sure that the controller is correctly programmed the flow switch and pump contact are connected in series so that the unit can only come in operation when the water pumps are running and the water flow is sufficient the heater tape for the drain system field supply is powered up via a separate power supply A To prevent the evaporator from freezing and to avoid damage to the LCD displays of the digital controller never switch off the power supply during winter Part 4 Commissioning and Test Run 4 7 Pre Test Run Checks ESIE98 03 4 8 Part 4 Commissioning and Test Run ESIE98 03 Test Run 8 Operation Data 2 Test Run amp Operation Data Introduction The following tables give an overview of the measurements that you can do Use it as a guideline during commissioning For the location of the measurement points we refer to the piping and wiring diagrams in Part 1 Pressures Measurement Value Suction pressure 1 8 4 4 bar saturated pressure corresponding to leaving chilled water temperature Discharge pressure 5 7 15 8 bar saturated pressure corresponding to leaving condenser water temperature Maximum water pressure 10 bar i The minimum values are not valid in case of
12. OOC O B DIPSWITCH Address 3 ON t device LS A SW PCB board 1 PCB board 2 Address 1 Address 2 DIPSWITCH DIPSWITCH To on BEER OFF sw 1 2 3 4 5 6 SW 1 2 3 4 5 6 Part 1 System Outline 1 39 Wiring Layout ESIE98 03 3 4 Wiring Diagrams Overview The wiring diagrams of the following chiller types are displayed on the following pages Chiller type See page EUWA 40 60K X page 1 41 EUWA 80 120K X page 1 42 1 40 Part 1 System Outline ESIE98 03 Wiring Layout Wiring diagram EUWA 40 60K X IDEA DOC He FAS 293 75 76 al s y o a 7 Y 80 sp 8 3 3 F Be Kso e an 78 PS e E RIP i j pi 0P57 es eL y 012 me a 013 2 2 Z 2 Q 5 3 230 81 0P57 WON The 3OVA g 8 a Ea R 8 pS F8B KM Z FOB stl T gt E E 1 ba B2 B4 6 A TRS gt iva 2 omer 2 SUPPLY CONTROLLER 5 S FIELD SUPPLY 2 NOT POSS AS OPTION POSS AS OPTION OBLIGATORY g NOT OBLIGATORY g Yiss TIQUIDLINE SOLENOID VALVE Y145 LIQUID INJECTION VALVE OF THE COMPRESSOR Y135 70 CAPACITY STEP FOR COMPRESSOR Y125 40 CAPACITY STEP FOR COMPRESSOR Yrs 12 CAPACITY STEP F
13. then consult unit safety Unit safety screens on page 3 9 circuit safety Circuit safety screens on page 3 10 2 Find the cause of the alarm The system is repaired and correct it 3 Press to reset the m The LED goes out and the alarm screen is alarm deactivated m The first screen of the readout menu is displayed automatically E After resetting the alarm you can consult the safety information only using the history menu on page 2 32 4 Go to the second screen of The alarm status of each circuit is displayed the readout menu by press ing _ refer to page 2 24 5 If all circuits were shut The unit starts again down switch on the unit by pressing O 3 8 Part 3 Troubleshooting ESIE98 03 Overview of Fault Indications and Safeties Unit safety screens If a unit safety occurs the following screen is displayed Line n Display Description 1 UNIT SAFETY screen title 2 FLOW SUCH activated unit safety 3 INL OTL inlet outlet water temperature 4 AB ambient temperature Other unit safeties are emergency stop and freeze up Subscreens By pressing the a key you can consult the subscreens After 20 seconds these screens automatically disappear Subscreen 1 This screen shows information about the pressures of circuit 1 Line n Display Description 1 UNIT SAFETY screen title 2 HFI
14. ce Y12S SET 25 BAR Y13S B1P 42 DA HA siPH 514PH B2P 2 72 Y pH 7 SUCTION y STOPVALVE kK D me Ho OPTIONAL a IES Fm Y hy 3 2 E E Mm O z O S ss H A cory HFST gpro a aoo IICA MA KEE SAFETY VALVE Y14S Y AT 28 BAR LIH ir lt H f ONLY FOR e i 4 50 AND 60HP STRAINER Y15S D EVAPORATOR CONDENSER E A GC o OO Cee E KPN CHECKVAIVE lt FLARECONN I SCREW CONN FLANGECONN X PINCHED PIPE SPINNED PIPE 1 22 Part 1 System Outline ESIE98 03 Piping Layout Functional diagram The figure below displays the functional diagram of the refrigeration circuit of the chiller types EUWA 80 120K EUWA 80 120K O PS Water OUT nat i Y125 Go a 4 Y225 ae o OT E B RaT E Y135 5 a Ojj a gt uu Ea P Sal ae S2HP S15HP
15. 2 The inputs and outputs can also be consulted in the Input Output Menu on page 2 37 3 Available as an option Part 1 System Outline 1 45 Wiring Layout ESIE98 03 Example main rai terminals on field rail 112 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 8 11 p p 9 10 k p 9 9 911 8918 fh FL s OFF OFF OFF 5 12 P The numbers refer to ON operation 230 V3 24 V the items in the OFF i terminal connections SNO OperaHon FL flow switch P pump contact 1 46 Part 1 System Outline ESIE98 03 Part 2 Functional Description Introduction This part gives more detailed information on the functions and controls in the unit This information is used as background information for troubleshooting An extensive overview of the functioning of the controller is also given in this part Knowledge of the controller is indispensable to gain valuable information prior to servicing and troubleshooting What is in this part This parts contains the following chapters Topic See page 1 Functional Control page 2 3 2 The Digital Controller page 2 17 Part 2 Functional Description 2 1 ESIE98 03 2 2 Part 2 Functional Description ESIE98 03 Functional Control 1 Fu
16. ESIE97 02 General index controller COMPFESSOrtIMELS viii is A ae dd e 2 30 discharge temperature controller 0 0 000 cece eee eee 1 27 frontpaneel imade ane att ana euige Pes ed ete a a Ea ed os Gilet ape tad tee bine 2 18 general eet At o io eo art cc its a las 2 17 DIST ici ha A eee ee ee ete ane E 2 21 2 32 NATO Sey cen ere eta dea Arie A ty eerste tenet aes trance A a es apace ea 2 21 2 36 INPUV OUTDUL nc ama ores debe ee a dt nel ns eth dae tee 2 22 2 37 ES A Gene fern a ea etea Recs a a EAEg 2 29 PASSWOld ball ho dde EE A E EE E o where A E E 2 22 2 41 read out rei a e a e eae E eat aE Sl A ke E 2 21 2 24 remote control 2 27 SE PO N S sera nsaan ioniad A A A AA AAA E AA ts 2 21 2 26 SOMWANeTIMENS e ses tg oe yaa te A MON A AA Aa ata 4 2 30 Start Stop oor otc ed do a en dde lid ds 2 19 IMENSE 35 A eta ae RN a era ap need ca ano aed dda aed 2 21 2 30 USEM SCHINGS a a a tl Babe ae Me We taco an Rad o idea 2 21 2 27 D digital COMMONS Ho csr anes sedi er a TE AAA ra AE AA AS ASE 2 17 digital input essasi aes es ee eA AONE AEE Le AA aA hee ea A ES 3 4 3 5 digital InpUtS OUTPUTS sis tated Be oh yee de ease a GEE AL Se ea eel wed are leads 3 18 digital Output 00h eu rete peat ee ea A Sees PRE oe ee 3 4 3 6 discharge temperature controller 0 0 c ett eee 1 27 2 14 draining Olll eater ii is oh Seah hy id Ded cee anne ds de a 3 30 Mii a A e eee AAG ee cuales Elbe A ante dd Eat A ee a Mea ee 1 2
17. OBLIGATORY 1 3 DIGITAL OUTPUTS RELAYS SA C1 NOT compressor 1 star JSA C2 NO2 compressor 1 delta JSA C3 NO3 compressor 1 on JBA CA N08 pur BA C5 N0S JSA C12 N012 ov hez ZAR C5 N06 12 C1 ZAR CB NO8 40 C1 j 70 C1 248 C13 M019 70 C2 J22 C9 N09 NC9 fan 11 324A C13 N01 248 C8 NO8 40 C2 3228 C9 N09 NC9 fan 21 322A C10 NOI0 NCIO an 14 322A C1I NOVI MC11 fan 12 618 3228 CUI NOTI NC11 lan 2 23 il sad Lad Vy sod rd 6 output terminals ori EXAMPLE 7 ANALOG INPUTS IA 88 J1 024V ow pressure 1 contactor eoit ex waterpump IA BO 9240 low pressure 2 as it sii i dat remote enable disable enable disable Setpoint starlstop cimuit 1 tinut 2 78 n i 8 Y 4 7 OBLIGATORY FIOS FIS F126 F13 KTTS KTAS recommends according to EC standard 268 2 Switch box side FEDS WOTPOSS AE OPTION
18. Part name Code Function 1 Compressor M1C All compressors are semi hermetic screw types with an M2C oil separator and crankcase heater There are no suction or discharge valves and no oil pump is required 2 Air heat exchanger The air heat exchanger is of the cross fin coil type with condenser Hi X tubes and chromate coated waffle louvre fins The air cooling discharge is upward 3 Fan M11F All fan motors are directly driven single or two speed M14F motors M21F M24F 4 Water heat E The water heat exchanger is a direct expansion shell exchanger and tube type with refrigerant flowing through the tube evaporator and water flowing through the shell via baffle plates The internal finned tubes provide an extended surface creating a turbulence between the freon liquid as well as a gas improving capacity 5 Expansion valve The thermostatic expansion valve is set up to control the superheat between 5 C and 7 C 6 Dryer with charge The replaceable filter dryer will keep the refrigerant valve system dry It is equipped with a charge valve 7 High pressure S1PH The refrigerant circuit s contains 2 4 high pressure switch S14HP switches in order to act as a safety for the compressor to S2HP switch off S15HP 8 Water in and out The water connections exist out of flexible joints or gas let connections pipe connections straight to the evaporator 9 Liquid injection Y14S The liquid injection valve maintains the discharge solenoid
19. Troubleshooting ESIE98 03 Overview of Inputs and Outputs 1 Overview of Inputs and Outputs 1 1 What Is in This Chapter Introduction The first step in a troubleshooting sequence is to check the inputs and outputs In this chapter an overview is given Overview This chapter covers the following topics Topic See page 1 2 Overview of Inputs and Outputs of EUWA 40 60K X page 3 4 1 3 Overview of Inputs and Outputs of EUWA 80 120K X page 3 5 Part 3 Troubleshooting 3 3 Overview of Inputs and Outputs ESIE98 03 1 2 Overview of Inputs and Outputs of EUWA 40 60K X The following table describes the relation between the wiring diagram symbols and the wiring connections of chiller types EUWA 40 60K X We refer to the wiring diagram and the PCB layout to find the exact location on both wiring diagram and switch box Wiring diagram Wiring connec Type Detail symbol tion terminal Description analog input sensor R5T J2 B1 ambient temperature sensor R3T J2 B2 evaporator inlet water temperature sensor R4T J2 B3 evaporator outlet water temperature sensor transmitter B3A J2 B5 current transmitter optional B7V J2 B6 voltage transmitter optional B2P J1 B7 high pressure transmitter BiP J1 B8 low pressure transmitter digital input transducer R1P J4 ID3 reverse phase protector K17S J4 ID4 overcurrent relay K3A J4 ID5 auxiliary relay di
20. Gn ieee ch T M CURRENT TRANSFO op view of 4 PROCESS 7 DIGITAL INPUTS DIGITAL OUTPUTS RELAYS ANALOG INPUTS E gt KIF Kar sat coo A A 10 cl cc BE a KOK 4 1D1 1DCM1 low pressure switch 43 ID6 IDCM2 compr motor th prot 24 C6 NOB 12 42 B1 AVSS ambient measurement i a a MES ENG CHANGE No DES a E CM1 high pressure switch 33 ID7 IDCM2 flowswiteh J24 C7 NO7 25 4J2 B2 AVSS evaporator inlet t measurement T n 24 24 REVIS CLASS BR97W123AE 98 06 04 YY CM1 rev phase prot 43 ID8 IDCM2 controller bypass J6 C3 NO3 compressor on 324 C8 NO8 40 J2 B3 AVSS evaporator outlet measurement m 34 34 UT g EUWAB40 60K KX ICM overcurrent relay J3 ID9 IDCM2 dual setpoint J6 C4 NO 24 C13 N013 70 J2 B5 AVSS current M Cas Yaa ee DESCRIPTION OMSCHRIJVING J4 ID5 IDCM1 disch th prot 33 1D10 IDCM1 J6 C5 NO 422 C9 NO9 NC9 fanstep 1 J2 B6 AVSS voltage 7 13 j D Iso WIRING DIAGRAM 421 1011 1011R emergency stop 421 1012 1D12R J6 C12 N012 ev heater 422 C10 NO10 NC10 fanstep 2 422 C11 NO11 NC11 fanstep 3
21. 2xZHA7MLFLTE 2 pass 1 circuit shell amp tube dry expansion ES 470 Min 450 Max 1665 l min PVC nitril foam cross fin coil Hi X tubes and chromate coated waffle louvre fins 1920 m min vertical direct drive propeller 8 8 x 1300 W flexible joint Y 168 3 1 2 FPT R 134a 50 kg thermostatic expansion valve IDEMITSU FVC68D 101 2 Dimensions h x w x d 2156 x 2210 x 3980 mm 2156 x 2210 x 3980 mm 2156 x 2210 x 3980 mm Weight machine weight operation weight 2523 kg 2603 kg 2884 kg 3018 kg 3005 kg 3130 kg Casing material colour polyester painted galvanised steel plate ivory white Munsell code 5Y7 5 1 polyester painted galvanised steel plate ivory white Munsell code 5Y7 5 1 polyester painted galvanised steel plate ivory white Munsell code 5Y7 5 1 Sound power level Part 1 System Outline ESIE98 03 General Outline Model EUWA 80KX EUWA 100KX EUWA 120KX Safety 8 functional devices double TuV high pressure switches low pressure protection compressor motor thermal protector compressor motor overcurrent relay discharge temperature controller pressure relief valve on compressor reverse phase protector recycling and guard timer digital display controller with electronic temperature control freeze up protection Options all factory glycol applications mounted ZH leaving water evaporator 5
22. NY it is necessary to place a heatertape inside the drain system to prevent ice accumulation and possible drain blockage during winter time 7 no metal dust or burrs remain after grinding or drilling in the metal construction parts during the installation This facilitates the rust process and thus shortens the unit s lifetime 8 the operator has received the operation manual 9 the installer has received the installation manual 10 the air volume over the coil is adequate no blockage from paper plastic or air short cir cuit due to wrong positioning 11 all shut off valves indicated by a red label OPEN THIS VALVE BEFORE OPERATION are opened i EUWA 40 60K X 2 shut off valves EUWAS40 60K X 3 shut off valves EUWA 80 120K X 4 shut off valves EUWAS80 120K X 6 shut off valves B M T or D A In order to avoid compressor damage it is necessary to switch on the crankcase heater for at least 8 hours before starting the compressor after a long period of standstill 4 4 Part 4 Commissioning and Test Run ESIE98 03 Pre Test Run Checks 1 3 Water Piping Checks Checklist Water volume flow and pressure A checklist of water piping checks is given below Check if 1 the water volume is within the limits see table below 2 there is adequate water flow see table below 3 the water quality meets the stan
23. POSS AG OPTION 7 7 NOT OBLIGATORY YIBSY25S quid Tne OA 145 124 quid injection valve of the compressor circuit T call Vil Y238 VIS Y225 YRS YES y step Tor compressor circuit T Eire Twansfo digital inputs ansta supply controler wansfo control call STAPHTSTOPH high pressure switch circu areal S15 mala isolator switch SHTS 5125_ switch that disables circuit T ereallZ when closed SS ual setpoint selection switch EN contac ha closes T The pump Ts working Tonala Temotestarstop sae emergency stop push buon charge thermal protector circuit iaa high pressure switch circuit circuit 2 sensor for ambient temperature sensor for evaporator outlet water Temperaturo sensor Tor evaporator Inlet waler Temperature reverse phase protector leaf T circuit 2 Thermal protector compressor maor circuit T ciut Z Thermal protectors fan motors circuit Z Thermal protectors fan motors circuit T main earth terminal compressor motors circuit T circuit Z Tan motors circuit 2 fan motors circuit main supply terminals relay for discharge Thermal protector cireuil T EZ y relay compressor thermal protector circuit T ciruit 2 y relay for safeties circuit T circuit Z renit relay Tor circuit Y circuit 2
24. refrigerant charge refrigerant control oil type oil charge volume n of circuits semi hermetic single screw 2880 rpm 150 W 2 x ZH3LSFLYE 2 pass 1 circuit shell 8 tube dry expansion EHD S 270 SX BT 2400 Min 290 Max 1080 l min 14 4 kPa PVC nitril foam cross fin coil Hi X tubes and chromate coated waffle louvre fins 2 x 50 x 2 0mm 16 8 m2 1920 m min vertical direct drive propeller 8 8 x 500 W 750 rpm flexible joint Y 141 3 1 2 FPT compressor 2x1 NPT R 22 2x36 kg thermostatic expansion valve SUNISO 4GSD 751 2 semi hermetic single screw 2880 rpm 150 W 2 x ZH5MLFLYE 2 pass 1 circuit shell 8 tube dry expansion EHD S 310 SX BT 3000 Min 370 Max 1160 l min 19 25 kPa PVC nitril foam cross fin coil Hi X tubes and chromate coated waffle louvre fins 2 x 50 x 2 0mm 16 8 m2 2184 m min vertical direct drive propeller 8 8 x 1200 W 900 rpm flexible joint 141 3 1 2 FPT compressor 2x2x1 NPT R 22 2x40 kg thermostatic expansion valve SUNISO 4GSD 101 2 semi hermetic single screw 2880 rpm 150 W 2 x ZH5LLFLYE 2 pass 1 circuit shell amp tube dry expansion EHD S 420 SX BT 3600 Min 460 Max 1660 l min 13 kPa PVC nitril foam cross fin coil Hi X tubes and chromate coated waffle louvre fins 3 x 50 x 2 0mm 16 8 m2 1920 m3 min vertical direct drive propeller 8 8 x 1200 W 900 rpm flexible joint 168 3 1 2 FPT compressor 2x2x1 NPT R 22 2x47 kg
25. thermostatic expansion valve SUNISO 4GSD 101 2 Dimensions h x w x d 2156 x 3980 x 2210 mm 2156 x 3980 x 2210 mm 2156 x 3980 x 2210 mm Weight machine weight 2500 kg 2750 kg 2950 kg operation weight 2595 kg 2840 kg 3085 kg Casing material polyester painted galvanised steel polyester painted galvanised steel polyester painted galvanised steel plate plate plate colour ivory white Munsell code ivory white Munsell code ivory white Munsell code 5Y7 5 1 5Y7 5 1 5Y7 5 1 Sound power level 93 dB 96 dB 95 dB Part 1 System Outline ESIE98 03 General Outline Model EUWA 80K EUWA 100K EUWA 120K Safety amp functional devices double TuV high pressure switches low pressure protection compressor motor thermal protector compressor motor overcurrent relay discharge temperature controller pressure relief valve on compressor reverse phase protector recycling and guard timer digital display controller with electronic temperature control Options all factory glycol applications mounted ZH leaving water evaporator 5 C ZL leaving water evaporator 10 C OP10 anti freeze protection kit evaporator heatertape OP 12 suction stopvalve OP52 main isolator switch OP57 ampere amp voltmeter 1 Nominal conditions are as follows m entering leaving water temperature 12 7 C m ambient air temperature 35 C m power input is to
26. 1 page 2 40 Screen 13 To read the status of the fan speed relays of circuit 2 page 2 40 Screen 14 To read the status of the pump the alarm and the page 2 40 evaporator heater contacts O Password password Screen 1 To change the password page 2 41 1 You can assign a password protection to the set point menu refer to page 2 29 2 Only for EUWA 80 120K X 2 22 Part 2 Functional Description ESIE98 03 The Digital Controller 2 6 How to Read or Adjust Parameter Settings the Programming Procedure Programming The following flow chart explains the way to program procedure BEGIN Press the desired menu key zZ O Does the controller prompt you to give the password YES lt Enter the password using the _ key Press the Whey Select the desired screen using the 4_y key Z O Do you want to adjust a parameter setting YES A Select the parameter using the key Adjust the value using the _ key Z O Do you want to save the modifications YES Press e Press the activated menu key lt m n Do you want to adjust another parameter in the same screen Z O v Do you want to adjust a parameter in another screen NO 1 The display shows a screen of the last menu used 2 Only for the menus and Part 2 Functional Description 2 23 The Digital Controller ESIE98 03
27. 12 47 67 46 48 45 31 39 6 12 6 03 5 94 94 1 17 1 13 1 10 11 45 53 44 41 43 32 40 5 92 5 82 5 73 95 1 14 1 10 1 07 10 43 50 42 25 41 43 41 5 72 5 63 5 54 96 1 11 1 08 1 04 9 41 54 40 56 39 59 42 5 53 5 43 5 35 97 1 08 1 05 1 01 8 39 68 38 76 37 85 43 5 34 5 25 5 17 98 1 05 1 02 0 99 7 37 91 37 05 36 20 44 5 16 5 08 4 99 99 1 03 0 99 0 96 6 36 24 35 43 34 03 45 4 99 4 91 4 82 100 1 00 0 97 0 94 5 34 65 33 89 33 14 46 4 83 4 74 4 66 101 0 98 0 94 0 91 4 33 14 32 43 31 73 47 4 67 4 59 4 51 102 0 95 0 92 0 89 3 31 71 31 04 30 39 48 4 52 4 44 4 36 103 0 93 0 90 0 87 2 30 35 29 72 29 11 49 4 38 4 30 4 22 104 0 91 0 87 0 84 1 20 00 28 47 27 89 50 4 24 4 16 4 08 105 0 88 0 85 0 82 0 27 83 27 28 26 74 51 4 10 4 02 3 95 106 0 86 0 83 0 80 52 3 97 3 90 3 82 107 0 84 0 81 0 78 53 3 84 3 77 3 69 108 0 82 0 79 0 76 54 3 72 3 65 3 57 109 0 80 0 77 0 74 55 3 61 3 53 3 46 110 0 78 0 75 0 73 Part 3 Troubleshooting 3 17 Checking the Inputs and Outputs ESIE98 03 3 3 Checking the Digital Inputs and Outputs Input route Troubleshooting Output route In the following block diagram the digital input route from the transducer e g thermostat pressostat reverse phase etc to the PCB input is shown TRANSDUCER RELAISCONTACT PCB INPUT voltage free voltage free contact 230 V coil contact 24 V AC In most cases a malfunction occurs in the unit itself and not in the control circuit of the unit If however the latter is the ca
28. 15 06 69 2 35 2 29 2 24 36 157 50 151 80 140 20 15 14 89 14 68 14 48 70 2 28 2 22 2 17 35 149 30 144 00 138 80 16 14 31 14 12 13 93 71 2 21 2 16 2 10 34 141 60 136 60 131 80 17 13 75 13 57 13 40 72 2 15 2 10 2 04 33 134 40 129 70 125 20 18 13 22 13 06 12 89 73 2 09 2 04 1 98 32 127 60 123 20 118 90 19 12 72 12 56 12 41 74 2 03 1 98 1 93 31 121 20 117 10 113 10 20 12 23 12 09 11 95 75 1 97 1 92 1 87 30 115 10 111 30 107 50 21 11 77 11 63 11 07 76 1 92 1 87 1 82 29 109 30 105 70 102 20 22 11 32 11 20 11 07 77 1 86 1 81 1 78 28 103 80 100 40 97 16 23 10 90 10 78 10 60 78 1 81 1 76 1 71 27 98 63 95 47 92 41 24 10 49 10 38 10 27 79 1 76 1 71 1 68 26 93 75 90 80 87 93 25 10 10 10 00 9 90 80 1 71 1 66 1 62 25 89 15 86 39 83 70 26 9 73 9 63 9 52 81 1 66 1 62 1 57 24 84 82 82 22 79 71 27 9 38 9 28 9 18 82 1 62 1 57 1 53 23 80 72 78 29 75 93 28 9 04 8 94 8 84 83 1 57 1 53 1 49 22 76 85 74 58 72 36 29 8 72 8 62 8 52 84 1 53 1 49 1 44 21 73 20 71 07 68 99 30 8 41 8 31 8 21 85 1 49 1 45 1 40 20 69 74 67 74 65 80 31 8 11 8 01 7 91 86 1 45 1 41 1 37 19 66 42 64 54 62 72 32 7 82 7 72 7 62 87 1 41 1 37 1 33 18 63 27 61 52 59 81 33 7 55 7 45 7 35 88 1 37 1 33 1 29 17 60 30 58 66 57 05 34 7 28 7 19 7 09 89 1 34 1 30 1 26 16 57 49 55 95 54 44 35 7 03 6 94 6 84 90 1 30 1 26 1 22 15 54 83 53 39 51 97 36 6 79 6 69 6 60 91 1 27 1 23 1 19 14 52 31 50 96 49 83 37 6 56 6 46 6 37 92 1 23 1 20 1 16 13 49 93 48 66 47 12 38 6 33 6 24 6 15 93 1 20 1 16 1 13
29. 2 2 Solubility in water 25 C 1 bar g kg 1 7 Dynamic viscosity 25 C boiling liquid mPa s 0 205 Dynamic viscosity 25 C saturated vapour mPa s 0 012 Thermal conductivity 25 C boiling liquid mW m K 82 3 Thermal conductivity 25 C saturated vapour mW m K 14 3 Data R134a versus The following table compares the working values of R 134a with R 12 The used symbols are R12 m compression ratio p Po m volumetric refrigerating effect do th m compressor discharge ty m coefficient of performance COP E y R 134a R 12 to Pc Po oth th Ex to Pc Po o th th Ex C kJ m C C kJ m C 25 9 51 748 59 1 2 8 25 7 78 822 62 6 2 9 20 7 63 942 57 7 3 2 20 6 37 1012 60 8 3 3 15 6 19 1176 56 5 3 7 15 5 27 1235 59 3 3 8 10 5 05 1455 55 4 4 2 10 4 39 1495 57 9 4 3 5 4 17 1785 54 5 4 9 5 3 68 1797 56 6 5 0 0 3 46 2174 53 7 5 8 0 3 11 2146 55 6 5 8 Part 4 Commissioning and Test Run 4 13 Refrigerant R 134a ESIE98 03 Diagrams The following diagrams give a visual view of the comparisons P Py te C R 134a 9 ye 60 8 i R 12 Ta 58 6 5 56 4 a to sn 10 K sge d to sh 10 K u 40 C t 40 C 2 52 Ta tc sc 5 K tc sc 5 K 50 30 ty C 5 0 5 10 15 20 25 30 to E Compression ratio Compressor discharge temperature Gon
30. 5 1 5Y7 5 1 Sound power level 91 dB 97 dB 95 dB Part 1 System Outline ESIE98 03 General Outline Model EUWA 40KX EUWA 50KX EUWA 60KX Safety 8 functional devices double TuV high pressure switches low pressure protection compressor motor thermal protector compressor motor overcurrent relay discharge temperature controller pressure relief valve on compressor reverse phase protector recycling and guard timer digital display controller with electronic temperature control freeze up protection Options all factory glycol applications mounted ZH leaving water evaporator 5 C ZL leaving water evaporator 10 C OPO3 dual pressure relief valve condenser OP 10 anti freeze protection kit evaporator heatertape OP52 main isolator switch OP57 ampere amp voltmeter 1 Nominal conditions are as follows m entering leaving water temperature 12 7 C m ambient air temperature 35 C m power input is total input compressor control circuit fans pumps m leaving evaporator water temperature from 4 C to 20 C pull down condition to 25 C Part 1 System Outline 1 9 General Outline ESIE98 03 EUWA 80 120KX In the following table you will find the technical specifications of chiller types EUWA 80 120KX Model EUWA 80KX EUWA 100KX EUWA 120KX Nominal cooling capacity Nominal cooling input
31. C ZL leaving water evaporator 10 C OPO3 dual pressure relief valve condenser OP 10 anti freeze protection kit evaporator heatertape OP52 main isolator switch OP57 ampere amp voltmeter 1 Nominal conditions are as follows m entering leaving water temperature 12 7 C m ambient air temperature 35 C m power input is total input compressor control circuit fans pumps m leaving evaporator water temperature from 4 C to 20 C pull down condition to 25 C Some of the data of EUWA 80 120KX were not available when this Service Manual was composed Therefore we refer to Engineering Data to obtain this information Part 1 System Outline 1 11 General Outline ESIE98 03 1 3 Electrical specifications EUWA 40 120K In the following table you will find the electrical specifications of chiller type EUWA 40 120K Model EUWA 40K EUWA 50K EUWA 60K EUWA 80K EUWA 100K EUWA 120K Power supply Y1 Y1 Y1 Y1 Y1 Y1 Compressor phase 3 37 3 3 3 3 starting current 129A 171A 234A 129A 171A 234A max running current 87A 111A 133 A 87A 111A 133A starting method star delta star delta star delta star delta star delta star delta voltage 400 V 400 V 400 V 400 V 400 V 400 V nominal running current 61A 80A 94A 61A 80A 94 A Nominal distribution system voltage phase 3 3 3 3 3 3 frequency 50 Hz 50 Hz 50 Hz 50 Hz 50 Hz 50 Hz voltage 400 V 400 V 400 V 400 V 400
32. Case of an Alarm page 2 20 2 5 Menu Overview page 2 21 2 6 How to Read or Adjust Parameter Settings the Programming Procedure page 2 23 2 7 Read out Menu page 2 24 2 8 Set Points Menu page 2 26 2 9 User Settings Menu page 2 27 2 10 W Software Timers Menu page 2 30 2 11 W History Menu page 2 32 2 12 Info Menu page 2 36 2 13 amp Input Output Menu page 2 37 2 14 Password Menu page 2 41 Part 2 Functional Description 2 17 The Digital Controller ESIE98 03 2 2 The Digital Controller Digital controller The EUWA 40 120K X units are equipped with a digital controller offering a user friendly way to configure use and maintain the unit The digital controller consists of m an alphanumeric LCD display m 14keys 5 general keys and 8 menu keys m 10 LEDs next to the menu keys indicating the selected menu Front panel The illustration below shows the front panel of the controller with open cover read out set points user settings timers history information input output password not used start stop alarm _ scroll through screens change value enter key DAIKIN v MANUAL COOLING TER 22 How to go from one Each menu contains a number of screens You can go from one screen to another using the _ key screen to another In the upper left corner of the screen you will find
33. Circulating water lt 20 C supply water Items to be controlled pH at 25 C 6 8 8 0 6 8 8 0 corrosion scale Electrical conductivity mS m lt 40 lt 30 corrosion scale at 25 C Chloride ion mg CI lt 50 lt 50 corrosion Sulfate ion mg SO 7 lt 50 lt 50 corrosion M alkalinity pH 4 8 mg CaCOz I lt 50 lt 50 scale Total hardness mg CaCOz I lt 70 lt 70 scale Calcium hardness mg CaCO I lt 50 lt 50 scale Silica ion mg SiO l lt 30 lt 30 scale Items to be referred to lron mg Fell lt 1 0 lt 0 3 corrosion scale Copper mg Cu l lt 1 0 lt 0 1 corrosion Sulphide ion mg S 11 not detectable not detectable corrosion Ammonium ion mg NH lt 1 0 lt 0 1 corrosion Remaining chloride mg Cl l lt 0 3 lt 0 3 corrosion Free carbide mg CO lt 4 0 lt 4 0 corrosion Stability index corrosion scale 4 6 Part 4 Commissioning and Test Run ESIE98 03 Pre Test Run Checks 1 4 Electrical Checks Checklist A checklist of electrical checks is given below Check if main fuses earth leak detector and main isolator are installed An overview of the fuses is given on page 3 19 the main power supply voltage deviates less than 10 from the nominal value the flow switch and pump contact are properly wired up the optional wiring for remote indication is installed
34. Close the liquid line valve at the condenser outlet in order to prevent the condenser pressure from forcing liquid into the cylinder 7 Slowly open the 3 8 charging port valve while the compressor is running 40 and charge liquid at a fast rate to prevent the compressor from cutting out on low pressure control The refrigerant flow can also be controlled by the cylinder valve to avoid ending up with a hose full of liquid refrigerant The same result will be obtained by closing the cylinder valve when the charging is finished This will avoid a charging line full of liquid refrigerant A Stop charging if there is a rapid rise in the discharge pressure 8 Close the charging port valve 9 Open the liquid line valve at the condenser outlet 10 Check the operating unit If the sight glass is clear and high pressure and low pressure appear normal then the unit is correctly charged A Make sure that the compressor rotates at 100 for at least 15 minutes This is to assure stabilization 11 Disconnect the charging line from the 3 8 charging valve 12 Close the service valves 13 Replace the caps on the cylinder valve and the charging valve 3 32 Part 3 Troubleshooting ESIE98 03 Troubleshooting Vapour charging This method is mainly used for smaller systems However trim charging through the schroeder valve mounted on the suction line of the unit is possible Follow the fol
35. Description Possible settings 1 SETPOINT PASSUORD screen title 2 PASSUGRO NEEDED TO assign password protection to ZN CHANGE SETPOINTS set point menu Part 2 Functional Description 2 29 The Digital Controller ESIE98 03 2 10 Software timers Screen 1 Screen 2 Screen 3 Overview timers Software Timers Menu Using this menu you can read the actual value of the software timers This menu provides 3 screens This screen shows the actual value of the general timers Line n Display Description 1 GENERAL TERS screen title 2 LOADUP delay timer for loading up during countdown the unit is unable to enter a higher thermostat step default 180 s DUN delay timer for loaddown during countdown the unit is unable to enter a lower thermostat step default 20 s 3 FLOWSTART delay timer to enable a continuous water flow through the evaporator before start up of the compressor default 15 s FLOWSTOP delay timer that starts counting when the water flow through the evaporator stops during normal operation if the water flow has not restarted during the countdown the unit will shut down default 5 s 4 COMPR STARTED delay timer to start the next compressor used in manual mode or when only one thermostat step is set up default 10 s This screen shows the actual value of the compressor timers Line n Display Description 1 COMPRES
36. FEAG OUTMONU see c hh dees ah cs oh Sod eee Manse Da AN 2 21 2 24 refrigerant characters ee i ities tad a nn dao cd silat state s sra 4 13 AA E A ig gh aa at Ma aot 5 4 refrigerantes sas tant e oe ee Tn Saeed Goh are oe ede eee oda RT 3 32 4 11 refrigeration circuit ambient temperature SeNnSOr 2 2 eee 1 27 COMPIOS SO sei 5 te ase tea de ae ls he ot oe iat ae dad a cc onda lot ded tide ada 1 26 CONGSNSESN nnn ve Rove A aa hee AA Ladend A eared 1 26 description setaa aa aaa e AE Se Rias Ptc 1 22 1 23 1 24 1 25 discharge temperature controller 0 0 0 eee 1 27 diye sirs Ser soe ota teed a cee de race a ents ae Sade Seta dep SO a Bn A ae ee ae 1 26 OVapOratOle window es eels ee La ORR eee ke ae ee ee ea oes 1 26 EXPANSION valvo ii A A ae eee ee eee et 1 26 TAP a 3 26 NI TON 1 26 head pressure Stop Valve ee eee een eee nen paa eee 1 26 high pressure SWITCH es ra ii ote vlog acne tape ave atte alt Gagan rag tna ace wena ae a 1 26 high pressure transmitter nasas ee ee eee eee teen eee e eee eeee 1 26 liquid injection solenoid valve 2 0 ete 1 26 liquid line solenoid valve 2 0 0 ce teens 1 26 ligula STOP v le uaia e cnet a Ens 1 27 low pressure transmitter 0 tte eee ae 1 26 MAIN parts sve eee eg a eee eee alone Ada Oe wine Mpa eee ete 1 26 SIGE GlASS i e la Bide nd Mt E aS eee 1 27 unloading solenoid valve 0 0 cette eee 1 26 water temperature sensor 20 00 eee eee 1 27 remote contr
37. Inputs and Outputs ESIE98 03 Wiring diagram Wiring connec Type Detail symbol tion terminal Description digital output contact K3M J5A C1 star contactor for circuit 1 K2M J5A C2 delta contactor for circuit 1 KiM J6A C3 compressor on for circuit 1 H1P J6A C4 general operation and pump contact H2P J6A C5 alarm indication E3H J6A C12 evaporator heater optional K6M J5B C1 star contactor for circuit 2 K5M J5B C2 delta contactor for circuit 2 K4M J6B C3 compressor on for circuit 2 transducer Y11S J24A C6 12 capacity step compressor for circuit 1 Y12S J24A C8 40 capacity step compressor for circuit 1 Y13S J24A C13 70 capacity step compressor for circuit 1 K7F J22A C9 fan control 1 contactor for circuit 1 K8F J22A C10 fan control 2 contactor for circuit 1 K9OF J22A C11 fan control 3 contactor for circuit 1 Y21S J24B C6 12 capacity step compressor for circuit 2 Y22S J24B C8 40 capacity step compressor for circuit 2 Y23S J24B C13 70 capacity step compressor for circuit 2 K10F J22B C9 fan control 1 contactor for circuit 2 K11F J22B C10 fan control 2 contactor for circuit 2 K12F J22B C11 fan control 3 contactor for circuit 2 Part 3 Troubleshooting ESIE98 03 Overview of Fault Indications and Safeties 2 Overview of Fault Indications and Safeties 2 1 What Is in this Chapter Introduction In the first stage of the troubleshooting sequence it is important to interpret the faul
38. Pressure Control on page 2 7 15 Sight glass with The sight glass with moisture indicator is used to check moisture indicator the refrigerant shortage and or moisture level in the system 16 Water R3T R4T The water temperature sensors are used to control the temperature thermostat function in the outlet or inlet water control sensor They can also act as safety 17 Liquid stop valve The liquid stop valve shuts off the liquid line in case of pump down and in case of the procedure to replace the drier filter Refer to 4 6 Filter Procedure on page 3 29 18 Discharge s3T The discharge temperature protector uses bimetals to temperature S4T control the discharge temperature protector Details are given in 1 2 Technical Specifications on page 1 4 The following pictures give you a visual view of the different parts of the refrigeration circuit fans condensers compressors Part 1 System Outline 1 27 Piping Layout ESIE98 03 discharge shut off valve low pressure high pressure P unloader gnp transmitter transmitter valves Compressor F Type oildrain of oil separator charge valve liquid line liquid stop low pressure evaporator solenoid valve valve service port a es b l T E gt inlet water temperature sensor inlet water sight glass expansion moisture indicator yalve filter drier charge valve 3 8
39. The purpose of this part is to give an outline of all the relevant elements in an installation of the EUWA 40 120K X chiller types Once all the elements of the installation are described in short and the installation set up is understood a functional description of all elements will be given in the following parts of this book This part contains the following chapters Topic See page 1 General Outline page 1 3 2 Piping Layout page 1 21 3 Wiring Layout page 1 31 Part 1 System Outline 1 1 ESIE98 03 Part 1 System Outline ESIE98 03 General Outline 1 General Outline 1 1 What Is in This Chapter Introduction In this chapter you will find the outlook drawing and the installation outline of the air cooled water chillers EUWA 40 120K X Overview This chapter covers the following topics Topic See page 1 2 Technical Specifications page 1 4 1 3 Electrical specifications page 1 12 1 4 Outlook Drawing page 1 14 1 5 Installation Outline page 1 19 Part 1 System Outline 1 3 General Outline ESIE98 03 1 2 Technical Specifications EUWA 40 60K In the following table you will find the technical specifications of chiller types EUWA 40 60K Capacity steps Model EUWA 40K EUWA 50K EUWA 60K Nominal cooling capacity 101 kW 129 kW 161 kW Nominal cooling input BBO Be
40. V 400 V voltage tolerance 10 V 10 V 10 V 10 V 10 V 10 V Control circuit phase 1 1 1 te de 1 recommended fuses factory installed factory installed factory installed factory installed factory installed factory installed voltage 230 V 230 V 230 V 230 V 230 V 230 V Unit nominal running current 71A 94 A 108 A 142A 188 A 212A starting current 129A 171A 234 A 226 A 296 A 381 A recommended fuses 3x 125 aM 3 x 160 aM 3 x 160 aM 3 x 200 aM 3 x 250 aM 3x 315 aM 97A 125A 147 A 194 A 250 A 294A max running current 1 Nominal conditions are as follows entering leaving water temperature 12 7 C ambient air temperature 35 C power input is total input compressor control circuit leaving evaporator water temperature from 4 C to 20 C pull down condition to 25 C Part 1 System Outline ESIE98 03 General Outline EUWA 40 120KX In the following table you will find the electrical specifications of chiller types EUWA 40 120KX recommended fuses Nominal distribution system voltage phase frequency voltage voltage tolerance Control circuit factory installed 3 50 Hz 400 V 230 V 10 V factory installed 3 50 Hz 400 V 230 V 10 V factory installed 3 50 Hz 400 V 230 V 10 V factory installed 3 50 Hz 400 V 230 V 10 V Model EUWA 40KX EUWA 50KX EUWA 60KX EUWA 80KX EUWA 100KX E
41. a screen indicator indicating whether there is a previous or next screen An overview is given below The screen indicator indicates that you can return to the previous screen i go to the next screen h either return to the previous screen or go to the next screen Screen detail Each screen contains 4 lines which give information about a setting a description and an entry field The entry fields can be adjusted using the _ key The cursor is marked by the sign _ You can move the cursor between the screen indicator and the entry fields using the key You can move the cursor directly to the screen indicator by pressing the active menu key _ screen this is line 1 TITLE indicator yaaa 7 line 2 value 1 line 3 value 2 line 4 value 3 cursor information entry field il Make sure that the cursor is at the screen indicator position when scrolling through the screens A To avoid damage to the LCD display of the digital controller never switch off the power supply during winter 2 18 Part 2 Functional Description ESIE98 03 The Digital Controller 2 3 Start Stop and Temperature Setting At power on Remote start stop How to start or stop Emergency stop Temperature setting m The initialization takes 10 seconds m The controller automatically enters the readout menu displaying the first read out screen The procedure to start or stop the unit depends on
42. are optionally available for EUWA 40 120KX Code Description OP03 dual pressure relief valve condenser OP10 evaporator heatertape OP52 main isolator switch OP57 A meter V meter ZH glycol applications leaving water evaporator 5 C ZL glycol applications leaving water evaporator 10 C The following photo gives a visual view of field wiring terminals Part 1 System Outline 1 43 Wiring Layout ESIE98 03 EUWA 40 60K X location location in switchbox ees field wiring Pef ur uz is L field wiring EUWA 40 60K X location in wiring diagram examples EUWA 40 60K X EUWA 40 60K X terminal connections ltem Code Description Terminals Remarks 1 L1 L2 L3 PE power supply to unit L1 L2 L3 PE 2 138 mains isolator switch L1 L2 L3 3 3 10S dual set point switch 76 78 4 S6S remote start stop 76 79 1 2 5 S8L S9L flow switch pump contact 75 77 2 8 H2P alarm indication 71 72 2 9 H3P operation compressor indication 80 81 2 11 H1P general operation indication and pump contact 73 74 2 12 E3H evaporator heater 1 2 3 Remarks 1 These require programming see page 2 27 2 The inputs and outputs can also be consulted in the Input Output Menu on page 2 37 3 Available as an option Example main rail termi
43. current transmitter for circuit T circuit Z Tigh pressure transmilier for circuit Y circuit Z Tow pressure transmitter for cul creuit 2 PROCESS TOLER Current transfo for circuit 1 circuit 2 ENG CHANGE No DATE sw 123456 sw 123486 BR97W123AE 98 06 04 VE JEUWAB80 120K KX DESCRIPTION OMSCHRIJVING WIRING DIAGRAM DAIKIN EUROPENV eee 0T51166 1 OOSTENDE BELGIE Part 1 System Outline 1 42 ESIE98 03 Wiring Layout 3 5 Field Wiring Schematic drawings Field wiring components overview Options for EUWA 40 120K Options for EUWA 40 120KX Field wiring view The schematic drawings on the following pages will help you to locate the field wiring connections on the wiring diagrams and the switch boxes The tables on the following pages give an overview of all possible field wiring connections for each unit The item numbers will be repeated throughout the explanation to show the position on both wiring diagram and switch box layout The following devices are optionally available for EUWA 40 120K Code Description OP10 evaporator heatertape OP12 suction stopvalve OP52 main isolator switch OP57 A meter V meter EKEM emergency operation ZH glycol applications leaving water evaporator 5 C ZL glycol applications leaving water evaporator 10 C The following devices
44. display of The photo below displays the outlook of the chiller type EUWA 40 60K X EUWA 40 120K X EUWA 80 120K The figure below displays the outlook of the chiller type EUWA 80 120K DETAIL A 1 10 2210 E 3980 1000 AIR AIR AIR AIR AIR AIR 3000 2156 ZZA Required space around the unit for service and air intake o alve 2 8 x hole for fixation 020 40 CHILLED WATER TOESTEL A B c D IN OUT IEUWAB80K 2280 970 287 387 9 141 3 9 141 3 IEUWAB100K 2280 970 287 387 9 141 3 141 3 EUWAB120k 2250 1013 362 512 168 3 9 168 3 For a description of the components of the outlook drawings refer to Main components table on page 1 18 Part 1 System Outline General Outline ESIE98 03 EUWA 40 60KX The figure below displays the outlook of the chiller type EUWA 40 60KX 1110 173 3980 AIR AIR AIR AIR a a AIR AIR AIR AIR AIR a 4 2135 DETAIL A ve ol d LA jo a 42 fixation holes 1012 5 E E A Te 5 8 x hole for fixation 920 O 16 20 17 E A El DETAIL A 1 10 CHILLED WATER i TOESTEL A B c D IN EUWA 40KX 1530 100 om 12
45. head pressure control Temperatures Measurement Value Leaving water temperature between 4 20 C Outdoor temperature between 0 43 C Temperature difference air side between 10 15 C Temperature difference water side between 3 8 C Discharge temperature between 70 100 C Voltages Measurement Value Power supply voltage Within 10 of the rated voltage Phase imbalance Within 2 25 of the rated voltage Control circuit voltage 230 VAC for main electromagnetic switches 24 VDC for the controllers Part 4 Commissioning and Test Run 4 9 Test Run amp Operation Data ESIE98 03 Currents Unit Nominal current Maximum current Fuses EUWA 40K 71A 97 A 3x125 aM EUWA 40KX 76 Y1 130 T1 A 101 Y1 168 T1 A 3x125 Y1 3x200 T1 aM EUWA 50K 94 A 125 A 3x160 aM EUWA 50KX 104 Y1 186 T1 A 126 Y1 235 T1 A 3x160 Y1 3x250 T1 aM EUWA 60K 108 A 147 A 3x160 aM EUWA 60KX 114 Y1 205 T1 A 148 Y1 270 T1 A 3x160 Y1 3x315 T1 aM EUWA 80K 142 A 194 A 3x200 aM EUWA 80KX 152 Y1 260 T1 A 202 Y1 336 T1 A 3x200 Y1 3x400 T1 aM EUWA 100K 188 A 250 A 3x250 aM EUWA 100KX 208 Y1 372 T1 A 252 Y1 470 T1 A 3x250 Y1 3x500 T1 aM EUWA 120K 212A 294 A 3x315 aM EUWA 120KX 228 Y1 410 T1 A 296 Y1 540 T1 A 3x315 Y1 3x630 T1 aM Compressor Connect your pressure gauges on the suction and the discharg
46. kg thermostatic expansion valve IDEMITSU FVC68D 7 51 1 semi hermetic single screw 2880 rpm 150 W ZHA7SLFLYE ZHA7SLFLTE 2 pass 1 circuit shell amp tube dry expansion ES 220 2750 Min 200 Max 715 l min 20 kPa PVC nitril foam cross fin coil Hi X tubes and chromate coated waffle louvre fins 3 x 50 x 2 0mm 8 4 m2 1092 m min vertical direct drive propeller 4 4 x 1200 W 900 rpm flexible joint 114 3 1 2 FPT compressor 1 NPT R 134a 45 kg thermostatic expansion valve IDEMITSU FVC68D 101 1 semi hermetic single screw 2880 rpm 150 W ZHA7MLFLYE ZHA7MLFLTE 2 pass 1 circuit shell amp tube dry expansion ES 270 3600 Min 235 Max 950 l min 11 kPa PVC nitril foam cross fin coil Hi X tubes and chromate coated waffle louvre fins 3 x 50 x 2 0mm 8 4 m2 960 m3 min vertical direct drive propeller 4 4x 1200 W 900 rpm flexible joint Y 141 3 1 2 FPT compressor 1 NPT R 134a 50 kg thermostatic expansion valve IDEMITSU FVC68D 101 1 Dimensions h x w x d 2135 x 3980 x 1110 mm 2135 x 3980 x 1110 mm 2135 x 3980 x 1110 mm Weight machine weight 1391 kg 1600 kg 1705 kg operation weight 1439 kg 1655 kg 1798 kg Casing material polyester painted galvanised polyester painted galvanised polyester painted galvanised steel plate steel plate steel plate colour ivory white Munsell code ivory white Munsell code ivory white Munsell code 5Y7 5 1 5Y7
47. m the number of times a unit safety or circuit safety occurred m the unit status at the moment of the last shutdown The table below gives an overview of the screens and sub screens in this menu Activated safety Unit safety Circuit 1 safety Circuit 2 safety Screens Screen 1 Screen 2 Screen 3 Sub screens Subscreen 1 1 Subscreen 2 1 Subscreen 3 1 Subscreen 1 2 Subscreen 2 2 Subscreen 3 2 Subscreen 1 3 Subscreen 2 3 Subscreen 3 3 Subscreen 1 4 Subscreen 2 4 Subscreen 3 4 You can go from one screen to another using the _ key You can go from one sub screen to another and from a screen to a subscreen using the a key The subscreens automatically disappear after 20 seconds 2 32 Part 2 Functional Description ESIE98 03 The Digital Controller Screen 1 Subscreen 1 1 Subscreen 1 2 Subscreen 1 3 Subscreen 1 4 This screen shows the unit history Line n Display Description 1 UNIT HISTORY XXX x the total number of unit shutdowns 2 FLOW SWITCH the unit safety 3 INE GUTL inlet outlet water temperature 4 AMB ambient temperature This screen shows information about the pressures of circuit 1 Line n Display Description 1 UNIT HISTORY XXX screen title 2 HP high pressure refrigerant circuit 1 in bar and equiv
48. page 2 29 6 LEAD LAG SETTINGS To define the lead lag mode of both circuits page 2 29 only for EUWA 80 120K X 7 SETPOINT PASSUDRD To assign password protection to the set page 2 29 points menu Screen 1 You need to enter the correct password before you can consult the screens in this menu Line n Display Description 1 ENTER PASSWORD screen title 2 PASSWORD DODD to enter the correct password Screen 2 This screen provides the ability to activate remote control Line n Display Description Possible settings 1 REMOTE CONTROL screen title 2 REMOTE ON OFF to activate remote start stop GN The procedure to start or stop the unit is given in Start Stop and Temperature Setting on page page 2 19 Screen 3 This screen provides the ability to modify the control settings Line n Display Description Possible settings 1 CONTROL SETTINGS screen title 2 MODE to select the control mode MANUAL CONTROL INLET WATER CONTROL OUTLET WATER CONTROL 3 FY Fe fan speed circuit 1 2 manual mode OFF LOU MEDIUN HIGH 4 CIRI CIRC capacity step circuit 1 2 manual 0 40 10 100 mode Part 2 Functional Description 2 27 The Digital Controller ESIE98 03 Screen 4 This screen provides the ability to modify the thermostat parameters Line n Displa Description Lower Upper Ste Default Play p limit limit P 1 THERM SETTINGS scre
49. temperature sensor transmitter B3A J2A B5 current transmitter for circuit 1 optional B7V J2A B6 voltage transmitter for circuit 1 optional B2P J1A B7 high pressure transmitter circuit 1 B1P J1A B8 low pressure transmitter for circuit 1 B6A J1B B5 current transmitter for circuit 2 B5P J1B B7 high pressure transmitter for circuit 2 B4P J1B B8 low pressure transmitter for circuit 2 digital input transducer R1P J4A 1D3 reverse phase protector for circuit 1 K17S J4A ID4 overcurrent relay for circuit 1 K3A J4A ID5 auxiliary relay discharge thermal protector for circuit 1 K2A J4A ID6 auxiliary relay compressor thermal protector for circuit 1 R2P J4B ID3 reverse phase protector for circuit 2 K18S J4B ID4 overcurrent relay for circuit 2 K6A J4B ID5 auxiliary relay discharge thermal protector for circuit 2 K5A J4B ID6 auxiliary relay compressor thermal protector for circuit 2 contact S1PH J4A ID1 high pressure switch 1 for circuit 1 S14PH J3A 1D2 high pressure switch 2 for circuit 1 S8L S9L J3A ID7 flow switch pump contact J4A ID8 controller bypass optional 10S J4A ID9 dual set point selection switch S6S J3A 110 remote start stop switch S5E J21A 1D11 emergency stop button S2PH J4B ID1 high pressure switch 1 for circuit 2 S15PH J3B ID2 high pressure switch 2 for circuit 2 118 J3A 1D7 switch that disable circuit 1 when closed s12S J4A ID8 switch that disables circuit 2 when closed Part 3 Troubleshooting Overview of
50. the setting of the remote start stop For more information refer to page 2 27 To start or stop the unit proceed as follows Remote start stop Start or stop Action Result LED no start press lights up stop press goes off yes initial press O blinks start pull switch remote start lights up stop pull switch remote stop blinks The local start stop button VW must be enabled blinking before the remote start stop is active If the remote start stop is not enabled then the led is off In case of emergency switch off the unit by pushing the emergency stop button To adjust the inlet or outlet water temperature use the set points menu key refer to page 2 26 Part 2 Functional Description The Digital Controller ESIE98 03 2 4 What Happens in Case of an Alarm Two kinds of safety The units are equipped with two kinds of safety devices devices Unit alarm Circuit alarm Function Protects the unit in general Protects the individual circuits Description m all compressors are shut down m the compressor of the m the red LED inside the key lights corresponding circuit is shut down up m the red LED inside the key lights m the buzzer is activated ne m the buzzer is activated Action to Press to acknowledge the alarm Press io acknowledge the alarm take Result m The b
51. the unit leaks contact your dealer m Ifthe sight glass shows a wet condition or bubbles combined with a full refrigerant charge then it indicates an refrigerant imbalance or unstable running conditions If a dry condition is not appeared within 12 operating hours the filter drier must be changed Inspection checks and actions Remarks Clean the cooling ribs of the fan motor if it is dirty Inspection checks and actions Remarks Check the water condition 1 Drain the water from the air release plug 2 If the water is dirty replace all the water in the sys tem 3 Check the water connection Dirty water causes a cooling capacity drop as well as corrosion of the water heat exchanger and pipe Inspection checks and actions Remarks Check for any abnormal noise 1 Locate the noise producing section and search the cause 2 If the cause of the noise cannot be located contact your dealer Part 5 Maintenance Maintenance ESIE98 03 5 6 Part 5 Maintenance ESIE98 03 Appendix A Photo parts Introduction In order to find a visual view of some of the components the following list will give you the references of the parts according to photos integrated in this manual Parts versus The following table shows the page of the photo on which the part is pointed photos
52. title 2 4 CIFANSTEP 1 2 3 fan speed steps 1 2 3 circuit 1 OPEN CLOSED You can find more information in Fan Speed Control after Start up Head Pressure Control on page 2 7 Screen 13 This screen shows the status of the fan speed relays of circuit 2 Line n Display Description Possible settings 1 RELAY OUTPUTS screen title 2 4 Ce FANSTEP 1 2 3 fan speed steps 1 2 3 circuit 2 OPEN CLOSED You can find more information in Fan Speed Control after Start up Head Pressure Control on page 2 7 Screen 14 This screen shows the status of the pump the alarm and the evaporator heater contacts Line n Display Description Possible settings 1 RELAY CUTPUTS screen title 2 PURPCONTACT indicates the status of the pump OPEN CLOSED contact 3 GEN ALARM indicates the status of the OPEN CLOSED general alarm contact 4 EVAP HEATER indicates the status of the OPEN CLOSED evaporator heater contact You can find more information in Overview of Inputs and Outputs of EUWA 40 60K X on page 3 4 and in Overview of Inputs and Outputs of EUWA 80 120K X on page 3 5 2 40 Part 2 Functional Description ESIE98 03 The Digital Controller 2 14 Password Menu Password The password protects the access to m the user settings menu m the set points menu 6 The password is a 4 digit number between D000 and 9999 The units leave the factory with userpassword 0000 The general factory password is 1914 il To reset a pr
53. valve SUNISO 4GSD 101 1 semi hermetic single screw 2880 rpm 150 W ZH5LLFLYE 2 pass 1 circuit shell amp tube dry expansion EHS S 220 SX BT 21001 Min 230 Max 920 l min 23 kPa PVC nitril foam cross fin coil Hi X tubes and chromate coated waffle louvre fins 3 x 50 x 2 0mm 8 4 m2 960 m min vertical direct drive propeller 4 4 x 1200 W 900 rpm flexible joint Y 114 3 1 2 gas compressor 2x1 NPT R 22 45 kg thermostatic expansion valve SUNISO 4GSD 101 1 Dimensions h x w x d 2135 x 3980 x 1110 mm 2135 x 3980 x 1110 mm 2135 x 3980 x 1110 mm Weight machine weight 1205 kg 1345 kg 1530 kg operation weight 1245 kg 1385 kg 1585 kg Casing material polyester painted galvanised polyester painted galvanised polyester painted galvanised steel plate steel plate steel plate colour ivory white Munsell code ivory white Munsell code ivory white Munsell code 5Y7 5 1 5Y7 5 1 5Y7 5 1 1 4 Part 1 System Outline ESIE98 03 General Outline Model EUWA 40K EUWA 50K EUWA 60K Sound power level 88 dB 92 dB 94 dB Safety 8 functional devices m double TuV high pressure switches E low pressure protection compressor motor thermal protector compressor motor overcurrent relay E discharge temperature controller MH pressure relief valve on compressor m reverse phase protector E recycling and guard timer digital display controller with
54. 0 1400 0 168 3 0 168 3 For a description of the components of the outlook drawings refer to Main components table on page 1 18 Part 1 System Outline 1 17 General Outline ESIE98 03 Main components table The following table introduces the different parts of the outlook drawings for EUWA 40 120K X N Components 1 Evaporator 2 Condenser 3 Compressor 1 with pressure relief valve 4 Discharge stopvalve 5 Liquid stopvalve 6 Suction stopvalve optional 7 Chilled water in 8 Chilled water out 9 Water drain evaporator 10 Air purge evaporator 11 Leaving water temperature sensor 12 Entering temperature sensor 13 Ambient temperature sensor 14 Drier charge valve 15 Power supply intake 16 Emergency stop 17 Switch box 18 Digital display controller 19 Field wiring intake 20 Main isolator switch optional 21 Compressor 2 with pressure relief valve i Compressor 2 is only available for the chillers EUWA 80 120K X Standard for EUWAS40 120K X and EUWAD40 120K X Part 1 System Outline ESIE98 03 General Outline 1 5 Installation Outline Introduction The installation outline gives an overview of the main parts in a typical installation We consider three main parts m chiller m primary water circuit m secondary water circuit Typical installation The
55. 00 OUT 2000 259 5 374 EUWA 50KX 1350 9114 3 9114 3 2300 259 5 374 9114 3 9114 3 EUWA 60KX 1385 2280 286 5 o Hr 1000 FOR INSTALLATION 1000 3000 Required space DA around the unit for service and air intake TEI For a description of the components of the outlook drawings refer to Main components table on page 1 18 Part 1 System Outline ESIE98 03 General Outline EUWA 80 120KX The figure below displays the outlook of the chiller type EUWA 80 120KX DETAIL A 1 10 2210 FOR INSTALLATION 1000 3980 1000 AIR AIR AIR AIR AIR AIR 1000 7 3000 2156 E e DETAIL A Required space around the unit f or service and air intake 154 8 8 x hole tor fixation 920 000D 0000B0 40 334 E F A CHILLED WATER TOESTEL A B c D E F IN OUT EUWA 80KXY1 2280 998 287 387 1100 1100 9141 3 141 3 EUWA 100KXY1 2280 998 287 387 950 1400 0 168 3 168 3 EUWA 120KXY1 2250 1013 362 512 95
56. 2 19 temperature resistance values ooooooooocoomononrranancr rr 3 17 tehminal COnNSCtions ata aa ate ale ad a ade nel dence 1 44 1 45 AA a E ET RN 4 3 4 9 thermostat automatic MOde rita A ee ee eng A Aa A wees 25 A O 2 5 2 28 E RN 2 5 2 28 Manual MOE rie spi rpi A a oe TAR AAA ee Ai 25 A A ONO 2 5 2 28 StepdifferenCe vicio ei eee lcd da 2 5 2 28 OPS asta Ped EI IS AA A o AA a ES 2 5 STPL A che A A ee PS A Bod ts hee enced 2 5 2 28 thermostat COMI iii a a ian aba hens ee ep eek whe E ind at 2 5 thermostat parameters lt Zea a Sool a ida 2 6 2 28 OS MON Ue ieee 2568 e e EA e 2 21 2 30 AAA A Wola il ate auth O E E E ast neste 3 4 3 5 transmitters Taos le eo A E ee ee a E diate ee ee oe Wa a eee 3 4 3 5 transmitters high pressure transmitter 00 000 enyeni Aa anaue haie a a Kae d a a ala hhi 1 26 low Pressure MANSION cor areca aenea e e Pe enna te 1 26 TOUBISSHOOTING o E EAE EEA tot AE E E E NEEE E AN 3 21 U unloading solenoid valveS 0 kent eee 1 26 User settings Menu s A See ed ee See eee A a 2 21 2 27 W water calculation of the minimum water volume 00 0c cee 4 6 A pelea pad teen Mea at epee es etal Ge a es el tA i a ee walls 6 ate 4 5 IN AaNd OULEE connections ren a A MOM Rae Vale eee ena eal Sab dee ea ae eA 1 26 PE CSSU Ce ase MN a hath ta iy aod face ar Ure tan tel he ell ata anil rl Sposa re 4 5 QUIT etek A Ai li tds tiie deals 4 6 femperature SensOks decian A ob da e
57. 6 electrical specifications ii a nV RY LS Ma ge eee ae tes 1 12 1 13 emergency Stop ssi n ae Re eee A Aaa ani kek ha eee E 2 19 SQUAM SLAM Up vi aa A RAE nate E he Met Ne ai 2 12 CVAD OLALO to tara anaes neh ae dra gael ge SATAAN 1 26 EXPANSION MAME sis ia 484 eset eee eed eae eb ede e cate are ed 1 26 F factory menui aa a t 3 26 fan TO iii A A a LAA aj ee eds 1 26 locatione nn an A A ce Raa erate A a ae aa eee t 2 9 Sequeira Ae crated all ies tas tian als ine o o ole a e a N ahs 2 7 SLANTFUP SCQUONCO ss raa a a E a a a ae dated ara a 2 9 STOPS e rer Eea A hn a E E EAA NN 2 7 fan control procedure id o od ea eee agatha ere 2 8 TANS SPEC CONTROL bo ad A en Tae A A AE O ben eats 2 7 TAUIE INGICATION 5 mr ec cn aad ar cd wh eink a yee A oad Rhee LA E A A AS 3 8 field WING eset Sree AA AAA AA es A eth ane Bag ated ale ened 1 43 freeze up COM E A A A ate AOS 2 10 A CA 2 10 Protect votos cata rr Cp haduh PA AO y clay Aa wha oes 2 10 Tunetional diaQGramM oi A A AS E Aa cee oa aes 1 22 1 23 1 24 1 25 MUA a a A nea 3 19 H head pressure controli sss st ct A A A eee 2 7 head pressure Setback cimil a ee yl Wane ci 2 16 head pressure stop valve 0 0 0 0 cc tte teens 1 26 high PreSSUre SWITCH sata ie A idm a eed vet ala A tances 1 26 ESIE97 02 General index high pressure transmitter oo oooocooconorcco nono 1 26 history MO A ar rar 2 21 2 32 NUM A e e a 4 12 INTO MENU mi cl nO RA e EAS E
58. 90 l min 1565 l min EUWA 120K 3600 460 l min 1660 l min EUWA 120KX 450 l min 1665 l min Refer to Thermostat Control on page 2 5 Refer to calculation of the minimum water volume on the next page A The water pressure should not exceed the maximum working pressure of 10 bar Part 4 Commissioning and Test Run 4 5 Pre Test Run Checks ESIE98 03 Calculation of the The following calculation method is based on the fact that the water volume in a chiller should be large minimum water enough to prevent the compressor from excessive cycling Sufficient water volume will give a certain volume inertia to the system so that water or glycol temperature does not drop too fast when the unit turns on and that the temperature does not rise too fast when the unit turns off 05xQxt V mi 2xpxdx Cw with V Required system volume m Q Cooling capacity at the lowest capacity step of each chiller in the system W t Minimum cycling time allowed by the compressor s default 600 s P Specific mass of the fluid kg m default Pater 1000 kg m8 d Thermostat step difference K default 0 2 K for outlet water control and 0 5 K for inlet water control Cw Specific heat capacity of the fluid J kgK default Cw water 4186 J kgk Water quality In the table below you will find the required water quality specifications Tendency if out Evaporator water of criteria
59. 98 03 4 5 Pump Down Precautions The pump down operation can only be executed when m the unit is switched off m the pressure transmitters are installed m the system is not working in bypass mode i Bypass mode means the mode in which the electronic device is bypassed by an other optional electronic device This can be in case of failure of the electronic device Procedure To execute a pump down proceed as follows Step Action 1 Enter the password menu Refer to 2 Password Menu on page 2 41 2 Enter your password 3 Press until you see the circuit chiller It takes approximately 10 seconds In case of a double circuit select the circuit that you want to pump down 4 Close the liquid line stop valve 5 Press E 6 Switch on the unit to pump down by pressing O 7 When the buzzer sounds close the discharge stop valve 8 Press to stop the buzzer 9 Use a recovery unit to compartiment the rest of the refrigerant on the low pressure side i Compartimentation Pumping of the refrigerant from the low to the high pressure side using a pump out unit A gas bottle is not needed to recuperate the refrigerant Picture The following picture gives a visual view of the high pressure service port schroeder valve 3 28 Part 3 Troubleshooting ESIE98 03 Troubleshooting 4 6 Filter Procedure Filter core The following table explains how t
60. Call outs See page 70 page 1 29 40 page 1 29 12 page 1 29 ambient thermistor page 1 29 charge valve 3 8 page 1 28 Compressor F Type page 1 28 compressors EUWA 80 120K X page 1 27 condensers EUWA 80 120K X page 1 27 connection towards compressor indication page 3 13 contactors for star delta EUWA 80 120K X page 1 32 controller page 1 32 digital controller page 2 17 discharge safety valve page 3 13 discharge shut off valve page 1 28 discharge temperature protector page 2 14 emergency stop page 3 13 evaporator page 1 28 expansion valve page 1 28 fan contactors EUWA 80 120K X page 1 32 fans EUWA 80 120K X page 1 27 field wiring page 1 43 filter drier page 1 28 high pressure service port page 3 13 Appendix A Photo parts ESIE98 03 Call outs See page high pressure switch 1 page 3 13 high pressure switch 2 page 3 13 high pressure transmitter page 1 28 inlet water page 1 28 inlet water temperature sensor page 1 28 liquid line solenoid valve page 1 28 liquid stop valve page 1 28 low pressure service port page 1 28 low pressure transmitter page 1 28 moisture indicator page 1 28 oil drain of charge valve page 1 28 oil filter page 3 31 oil separator page 1 28 and page 3 31 outlet water connection page 1 29 outlet water temperature sensor page 1 29 outlook chiller EUWA 80 120K X page 1 15 overcurrent reset page 3 13
61. Capacity steps MAIN COMPONENTS Compressor type speed crankcase heater model x n Evaporator type min water volume system water flow rate nom water pressure drop insulation material Condenser type rows x stages x fin pitch face area nominal air flow discharge fan type n of fans n of motors x output nominal speed Piping connections evap water in outlet evaporator water drain relief device outlet Refrigerant circuit refrigerant type refrigerant charge refrigerant control oil type oil charge volume n of circuits semi hermetic single screw 2880 rpm 2xZHASLLFLYE 2xZHASLLFLTE 2 pass 1 circuit shell amp tube dry expansion ES 360 Min 300 Max 1165 l min PVC nitril foam cross fin coil Hi X tubes and chromate coated waffle louvre fins 1920 m min vertical direct drive propeller 8 8 x 500 W flexible joint 141 3 1 2 FPT R 134a 30 kg thermostatic expansion valve IDEMITSU FVC68D 7 51 2 semi hermetic single screw 2880 rpm 2xZHA7SLFLYE 2xZHA7SLFLTE 2 pass 1 circuit shell amp tube dry expansion ES 420 Min 390 Max 1565 l min PVC nitril foam cross fin coil Hi X tubes and chromate coated waffle louvre fins 1920 m min vertical direct drive propeller 8 8 x 1300 W flexible joint Y 168 3 1 2 FPT R 134a 45 kg thermostatic expansion valve IDEMITSU FVC68D 101 2 semi hermetic single screw 2880 rpm 2xZHA7MLFLYE
62. DAIKIN ESIE98 03 Service Manual EUWA 40 120K X Air cooled waterchillers Daikin Europe NV ESIE98 03 1 Introduction Part 1 Table of Contents 1 1 About This Manual v System Outline 1 1 1 General Outline 2 Piping Layout 3 Wiring Layout 1 1 What Is in This Chapter 1 3 1 2 Technical Specifications 1 4 1 3 Electrical specifications 1 12 1 4 Outlook Drawing 1 14 1 5 Installation Outline 1 19 2 1 What Is in This Chapter 1 21 2 2 Functional Diagram Refrigeration Circuit 1 22 2 3 Parts Table of the Refrigeration Circuit 1 26 3 1 What Is in This Chapter 1 31 3 2 Switch box Layout 1 32 3 3 Main PCB Layout 1 34 3 4 Wiring Diagrams 1 40 3 5 Field Wiring 1 43 Table of Contents ESIE98 03 Part 2 Functional Description 2 1 1 Functional Control 1 1 What Is in This Chapter 2 3 1 2 Operation Range 2 4 1 3 Thermostat Control 2 5 1 4 Fan Speed Control after Start up Head Pressure Control 2 7 1 5 Start up Sequence of Fans and Compressor 2 9 1 6 Freeze up Control 2 10 1 7 Lead lag Control only for EUWA 80 120K X 2 12 1 8 Discharge Temperature Protector 2 14 1 9 Heatertape optional 2 15 1 10 Head Pressure Setback 2 16 2 The Digital Controller 2 1 What Is in This Chapter 2 17 2 2 The Digital Controller 2 18 2 3 Start Stop and Temperature Setting 2 19 2 4 What Happens in Case of an Alarm 2 20 2 5 Menu Overview 2 21 2 6 How to Read or Adjust Parameter Settings the Progr
63. LIGATORY EXAMPLE n 80 13 ar 412 CONTROLLER PCB ANALOG INPUTS terminals on field rail 5 a WIRENUMBER IN 15 6 22 24 CONTROLLER PCB RELAY OUTPUTS main terminals in compressor switchbox oe ne ee ES 3 COMPRESSOR COMPRESSORSWITCHBOX1 K2A 33 4 21 CONTROLLER PCB DIGITAL INPUTS other terminals in compressor switchbox a A e j FAU FSU DOET AMD HAR SUTTCAEOX H3P INDICATION LAMP OPERATION COMPRESSOR 7 Hap H3P iia HIP FOB m e H2P INDICATION LAMP ALARM 2 earth wiring fowswitch e a siig FOB HIP INDICATION LAMP GENERAL OPERATION Cr sat a a FOB O FI2B AUTOFUSE FOR FANMOTORS Ey waterpump K3A 2 3 A a ee 4 FOB AUTOFUSE FOR SECONDARY OF TR3 3 wire number 13 s6s s10s A z 4 3yo F8B AUTOFUSE FOR SECONDARY OF TR1 i ini a3 max 4A output a 2 F6B AUTOFUSE FOR PRIMARY OF TR1 pumpconta i E gt E recommended fuses aM gG B uj toria namber3 x S 28 according to IEC standard 260 2 FAU FSU_ 4 FUSES FOR EVAPORATOR HEATER Or so Euo Suite EB cane F1U F2U F3U aM F4U FSU gG F 5 RIP F1U F2U F3U MAIN FUSES oe se ye T M4 E3H EVAPORATOR HEATER i d By EIHC CRANKCASE HEATER COMPRESSOR in 79 78 o 1E B7V V1 _ TRANSMITTER VOLTAGE 8 OPTIONAL C OP10 evaporator heatertape x B3A TRANSMITTER CURRENT in at 74 0P52 main isolator switch K178 C 0P57 A meter V meter a 1 14 1298 97 B2P TRANSMITTER HIGH PRESSURE i 4 1195 96 BIP TRANSMITTER LOW PRESSURE
64. OR COMPRESSOR TRS TRANSFO DIGITAL INPUTS 21 TRZ TRANSFO SUPPLY CONTROLLER er 5 TAT TRANSFO CONTROL CIRCUIT 2 ST4HP HIGH PRESSURE SWITCH atte aa air S135 5H MAIN ISOLATOR SWITCH 5105 DUAL SETPOINT SELECTION SWITCH e Sol CONTACT THAT CLOSES IF THE PUMP IS WORKING Sal FLOWSWITCH 5 foam ES REMOTE START STOP SWITCH aa SSE EMERGENCY STOP PUSHBUTTON ST DISCHARGE THERMAL PROTECTOR SHHP HIGH PRESSURE SWITCH RST SENSOR FOR AMBIENT TEMPERATURE 51 53 58 RaT SENSOR FOR EVAPORATOR OUTLET WATER TEMPERATURE t en RT SENSOR FOR EVAPORATOR INLET WATER TEMPERATURE RIP REVERSE PHASE PROTECTOR 3 8 8 8 QM THERMAL PROTECTOR COMPRESSOR MOTOR Q11F Q14F THERMAL PROTECTORS FAN MOTORS PE MAIN EARTH TERMINAL 53 53 mic COMPRESSORMOTOR 0 3 8 5 K2M KM M11F M14F _ FAN MOTORS 14 12 13 MAIN SUPPLY TERMINALS K3A AUXILIARY RELAY FOR DISCHARGE THERMAL PROTECTOR AL kF anj KBE At KoF Yiss EHC M K2A 3 K2A AUXILIARY RELAY COMPRESSOR THERMAL PROTECTOR Power Supply Power Supply z x 1 2 KIA AUXILIARY RELAY FOR SAFETIES 9 E KITS OVERCURRENT RELAY A2 3 50Hz 400V 1 50Hz 230V ule a 2 y KF FANCONTACTOR KIF FANCONTACTOR K3M STARCONTACTOR NOTES TO GO THROUGH BEFORE STARTING THE UNIT e STARCONTAGTOR KIM LINECONTACTOR 1 eL1 L2 L3 main terminals 5 Input terminals for fleldwiring 6 output terminals for fieldwiring 317 CONTROLLER PCB POWER SUPPLY 2 terminals on main rail EXAMPLE Eomboisetdorredor terminals for fans OB
65. PRESSURE SWITCH activated circuit safety 3 INL GUTL inlet outlet water temperature 4 ANB ambient temperature Other circuit safeties are overcurrent relay discharge thermal protector compressor motor thermal protector and reverse phase protector By pressing the key you can consult the subscreens After 20 seconds these screens automatically disappear This screen shows information about the pressures of circuit 1 Line n Display Description 1 CIRCUIT 1 2 SAFETY screen title 2 HP high pressure refrigerant circuit 1 in bar and equivalent in C 3 LP low pressure refrigerant circuit 1 in bar and equivalent in C This screen shows information about the pressures of circuit 2 Line n Display Description 1 CIRCUIT 1 2 SAFETY screen title 2 HPe high pressure refrigerant circuit 2 in bar and equivalent in C 3 LPE low pressure refrigerant circuit 2 in bar and equivalent in C Part 3 Troubleshooting ESIE98 03 Overview of Fault Indications and Safeties Subscreen 3 This screen shows information about the voltage and compressor current il This screen is available if optional voltage and current transmitters are installed Line n Display Description 1 CIRCUIT 1 2 SAFETY screen title 2 VOLTAGE voltage 3 CURRENT Ci compressor current circuit 1 4 CURRENT Ce c
66. R 2 21 2 36 inlet water temperature control ooccccccc anana aaaa 2 6 INPUT QUEMA a a yet ates davies a sek aabouie te tla ie ioe faces cee 2 22 2 37 inputs analog INpuls siii eii nra dee Gate as bade ae a daa a N a a meson 3 4 digital inputs 22 week a REE DEL Dee Sh a Redes eS Ee be REG Oke eb 3 4 3 5 digital QUIDUIS 2 is ee ot tained ENR e tai et hae alan ds pal adri 3 4 3 6 INPUIS QUIPUES i cree add da a laa E E ates aan 3 3 3 4 3 5 installation outline tii A a SR a a ean ete A 1 19 L leadrlag control ai a A A AN 2 12 liquid injection solenoid Valve ooooooooocooororoor nr 1 26 liquid line solenoid valve oooooooooooooooononncorr ro 1 26 liquid StOPiVA VE tamna A AA A Oa aes I AAA eas a AS Wael 1 27 low pressure transmitter oooooocccornnrcco rana 1 26 IMAI DOAK which red ia O Sede oie A ERAN aiden depute siete RE 1 34 main PCD IAVOULY socket A a ae Bek eect Hk ute aside attire an A Pape ete ae 1 34 maintenance COMPIESSO an 22 cay adi 4 o ork es ee ak ek AA e te ele See ea AG Bk A ae 5 4 COMINO EF issn cic ra Sete ets Gud eel ane A A A Gite da RR Ree ca ate 5 4 evaporators tae et tty alate ha aes a bbe i tate at ta RM A St ned me rs Da dacs 5 4 A yir tetas wa deen ee EE old Ma eek Si ao Soca Gaeta aU cel Stare Mae E a ante a s E 5 3 manpas wisg a a a e a il aae eh Ia Memes 5 4 Men OVETVIEW si ii p bat ach A Set a tae e Gerson Aa a a 2 21 O oil CONnCeNntratlONny aris ia el
67. SOR TIERS screen title 2 GRO AREC guard timer delay timer to prevent the compressor from 3 GRO 2 APEC 2 restarting after a shutdown default 60 s antirecycling delay timer to prevent the compressor from restarting after the compressor has started used to limit the number of restarts default 600 s This screen shows the actual value of the compressor start up timers Line n Display Description 1 COMPRESSOR TIERS screen title 2 STARTUPTINE 1 start up timer delay timer to limit the compressor capacity to STARTHDTINE 2 40 during the countdown default 140 s An overview of the software timers is shown in the example on the next page 2 30 Part 2 Functional Description The Digital Controller ESIE98 03 The following view shows an example of the working of the timers Example ISE sgt iT T gyse T reu days z days dajs y d s i days g das 1 dajs gt 7 Bej peaj jnoyym 7 g aun dn yeys OT aun dn peys Sor p peys udwoo 30g Peojumop dnpeo z puenb z dale pien6 9aJe T dojs moy SSI pues moj F moy uoneJado 2 31 Part 2 Functional Description The Digital Controller ESIE98 03 2 11 History Menu Reading safety info after shutdown Overview screens and subscreens Using this menu you can at all times read the information of the latest shutdowns
68. Tancontactor for circuit T circuit 2 Tancontactor for circuit T circuit Z Tancontactor for circuit 1 circuit 2 laconlator for circuit circuit Z porno TERMINAL w COMPRESSOR Sica winenumaen w Cante BerweeN COmPRESsORSHTEABOX 1 ko Main CREO fonpressreetbor TERMINAL w COMPRESSOR Seno winenumaen w Cante BerwEeN Compnessonswrcueox 2 io wan surTeHBOX 2 10 connections between PCBS position of jumpers and dipswitches USERTERMINAL E ADDRESS 3 DiPswircH eltacontactr for circuit 1 circuit 2 Tinecontactor for circuit T circuit 2 power supply pob A peb B relay outputs peb A y outputs peb B relay outputs pcb A a digital inputs peb B gal inputs peb A indican Tamp operation compressor Z Indication baud lamp operation compressor 1 Indication SW 123455 4150123 ajs ejeje Waldo PCO BOARD 1 DiPswircH DiPswircH atole for fanmotrs circuit T circu Z cial breakers with fuses for circuit T circuit Z atole for secondary of TAS alse Tor secondary o TAT aioe for primary of TAT uses Tor evaporator he main uses evaporator heater rankease jater compressor circuit eicalt2 voltage transmitter
69. UWA 120KX Power supply Y1 T1 Y1 T1 Y1 T1 Y1 T1 Y1 T1 Y1 T1 Compressor phase 3 3 3 3 3 3 starting current 172 A 363 A 193 A 400 A 250 A 504 A max running current 86 5 A 145 A 111 A 210A 133 A 245 A z 7 starting method star delta star delta star delta star delta star delta star delta voltage 400 V 230 V 400 V 230 V 400 V 230 V 400 V 230 V 400 V 230 V 400 V 230 V nominal running current 62 A 107A 89 A 161 A 99 A 180 A 62 A 107 A 89 A 161 A 99 A 180 A factory installed 3 50 Hz 400 V 230 V 10 V factory installed 3 50 Hz 400 V 230 V 10 V max running current phase 1 1 1 1 1 1 recommended fuses factory installed factory installed factory installed factory installed factory installed factory installed voltage 230 V 230 V 230 V 230 V 230 V 230 V Unit nominal running current 76 A 130A 104 A 186 A 114 A 205 A 152 A 260 A 208 A 372 A 228 A 410 A starting current 172 A 363 A 193 A 400 A 250 A 504 recommended fuses 3 x 125 aM 3 x 160 aM 3 x 160 aM 3 x 200 aM 3 x 250 aM 3x 315 aM 3 x 200 aM 3 x 250 aM 3x 315 aM 3 x 400 aM 3 x 500 aM 3 x 630 aM 101 A 168 A 126 A 235 A 148 A 270 A 202 A 336 A 252 A 470 A 296 A 540 A Nominal conditions are as follows entering leaving water temperature 12 7 C ambient air temperature 35 C power input is total input compressor control circuit leaving evaporator water temperature from 4 C to 20 C pull down condit
70. ach chiller type in the range EUWA 40 60K X Fuses EUWA 40K X EUWA 50K X EUWA 60K X F1U F2U F3U 3 x 125 aM 3 x 160 aM 3 x 160 aM F4U F5U 2 gG 2 gG 2 gG F6B 2x2A 2x2A 2x2A F8B 1A 1A 1A F9B 1A 1A 1A F12B 3x16A 3x16A 3x16A K17S 50A 64 A 77A The table below gives an overview of the fuses for each chiller type in the range EUWA 80 120K X EUWA 80 120K X Fuses EUWA 80JX EUWA 100JX EUWA 120JX F1U F2U F3U 3 x 200 aM 3 x 250 aM 3x315 aM F4U F5U 2 gG 2 gG 2 gG F6B 2x6A 2x6A 2x6A F8B 2A 2A 2A F9B 2A 2A 2A F10S F11S 3 x 100 aM 3x 125 aM 3x 160 aM F12B F13B 3x16A 3x16A 3x16A K17S K18S 50 A 64 A 77 A aM slowly reacting fuses gG fast reacting fuses means optional in case there is an evaporator heater Part 3 Troubleshooting 3 19 Checking the Inputs and Outputs ESIE98 03 3 20 Part 3 Troubleshooting ESIE98 03 Troubleshooting 4 Troubleshooting 4 1 What Is in This Chapter Introduction When a problem occurs you have to check all possible faults This chapter gives a general idea of where to look for defects Further the general procedures for refrigeration circuit repairs and for electrical circuit repairs are explained i Not all repair procedures are described Some procedures are considered common practice Overview This chapte
71. ae 100 70 40 100 70 40 100 70 40 MAIN COMPONENTS Compressor type speed crankcase heater model x n Evaporator type min water volume system water flow rate nom water pressure drop insulation material Condenser type rows x stages x fin pitch face area nominal air flow discharge fan type n of fans n of motors x output nominal speed Piping connections evap water in outlet evaporator water drain relief device outlet Refrigerant circuit refrigerant type refrigerant charge refrigerant control oil type oil charge volume n of circuits semi hermetic single screw 2880 rpm 150 W ZH3LSFLYE 2 pass 1 circuit shell 8 tube dry expansion EHS S 155 SX BT 17001 Min 185 Max 737 l min 21 kPa PVC nitril foam cross fin coil Hi X tubes and chromate coated waffle louvre fins 2 x 50 x 2 0mm 8 4 m2 960 m3 min vertical direct drive propeller 4 4x 500 W 750 rpm 3 gas 1 2 gas compressor 1 NPT R 22 33 kg thermostatic expansion valve SUNISO 4GSD 7 51 1 semi hermetic single screw 2880 rpm 150 W ZH5MLFLYE 2 pass 1 circuit shell amp tube dry expansion EHS S 155 SX BT 1700 I Min 187 5 Max 750 l min 25 kPa PVC nitril foam cross fin coil Hi X tubes and chromate coated waffle louvre fins 2 x 50 x 2 0mm 8 4 m2 1092 m min vertical direct drive propeller 4 4 x 1200 W 900 rpm 3 gas 1 2 gas compressor 2x1 NPT R 22 39 kg thermostatic expansion
72. alent in C 3 LP low pressure refrigerant circuit 1 in bar and equivalent in C This screen shows information about the pressures of circuit 2 Line n Display Description 1 UNI HISTORY XXX screen title 2 HPE high pressure refrigerant circuit 2 in bar and equivalent in C 3 LPe low pressure refrigerant circuit 2 in bar and equivalent in C This screen shows information about the voltage and compressor current il This screen is available if optional voltage and current transmitters are installed Line n Display Description 1 UNIT HISTORY XXX screen title 2 VOLTAGE voltage 3 CURRENT CI compressor current circuit 1 4 CURRENT Ce compressor current circuit 2 This screen shows information about the total running hours of the compressors and the capacity steps Line n Display Description 1 UNI HISTORY XXX screen title 2 RUNN HOURS 1 total running hours compressor circuit 1 3 RONN HOURS 2 total running hours compressor circuit 2 4 ci Ce compressor capacity steps Part 2 Functional Description 2 33 The Digital Controller ESIE98 03 Screen 2 This screen shows the circuit 1 history Line n Display Description 1 CLHISTORY XXX x the total number of circuit 1 shutdowns 2 HIGH PRESSURE SUNCH activated circuit 1 safety 3 INL GUTL i
73. amming Procedure 2 7 Read out Menu 2 24 2 8 Set Points Menu 2 26 2 9 User Settings Menu 2 27 2 10 Software Timers Menu 2 30 2 11 History Menu 2 32 2 12 E Info Menu 2 36 2 13 Input Output Menu 2 37 2 14 Password Menu 2 41 2 23 Table of Contents ESIE98 03 Part 3 Troubleshooting 3 1 1 Overview of Inputs and Outputs 1 1 What Is in This Chapter 3 3 1 2 Overview of Inputs and Outputs of EUWA 40 60K X 3 4 1 3 Overview of Inputs and Outputs of EUWA 80 120K X 3 5 2 Overview of Fault Indications and Safeties 2 1 What Is in this Chapter 3 7 2 2 Fault Indication 3 8 2 3 Safeties Overview 3 12 3 Checking the Inputs and Outputs 3 1 What Is in This Chapter 3 15 3 2 Checking the Temperature Sensors 3 16 3 3 Checking the Digital Inputs and Outputs 3 18 3 4 Checking the Power Supply and Fuses 3 19 4 Troubleshooting 4 1 What Is in This Chapter 3 21 4 2 Items to Be Checked 3 22 4 3 General Repair Procedures 3 24 4 4 Procedure for PCB Changing 3 25 4 5 Pump Down 3 28 4 6 Filter Procedure 3 29 4 7 Oil Changing Procedures 3 30 4 8 Refrigerant Charging 3 32 Table of Contents ESIE98 03 Part 4 Commissioning and Test Run 4 1 1 Pre Test Run Checks 1 1 What Is in This Chapter 4 3 1 2 General Checks 4 4 1 3 Water Piping Checks 4 5 1 4 Electrical Checks 4 7 2 Test Run amp Operation Data 3 Refrigerant R 134a 3 1 What Is in This Chapter 4 11 3 2 What Is New 4 12 3 3 Ch
74. aracteristics 4 13 Part 5 Maintenance 5 1 1 Maintenance 1 1 What Is in This Chapter 5 3 1 2 Maintenance of the Main Parts 5 4 1 3 Periodical Checks 5 5 Appendix A Photo parts A 1 Appendix B Drawings B 1 Index i iv Table of Contents ESIE98 03 Introduction 1 Introduction 1 1 About This Manual EUWA 40 120K X chiller types A Usage of the manual Approvals Using icons The Daikin EUWA 40 120K X air cooled water chillers are designed for outdoor installation The units are available in 6 standard sizes for cooling applications only The EUWA 40 120K X units can be combined with Daikin fan coil units or air handling units for air conditioning purposes They can also be used to supply water for process cooling Before starting up the unit for the first time make sure that it has been properly installed Consult the check lists in Pre Test Run Checks on page 4 3 You will find the following tools at the back of the manual m alist of parts in function of the integrated photos Refer to Appendix A Photo parts m alist of drawings Refer to Appendix B Drawings m an index Refer to Index The present service manual gives you all the information you need to do the necessary repair and maintenance tasks for these waterchillers operating with HCFC 22 EUWA 40 120K and HFC 134a EUWA 40 120KX It is intended for and should only be used by qualified engineers It is not intended
75. dards see table on the next page 4 the water piping is properly insulated 5 measurement points for temperature and pressure are available on the water circuit 6 the flow switch and pump are properly working 7 air purge points are installed on the high parts of the water piping and an air plug on the evaporator 8 drain taps are installed at the low points of the water piping to permit complete drainage during maintenance or shut down and drain plugs to drain the evaporator i Remove the air plug if you drain the evaporator 9 other parts of the water circuit are properly mounted and installed e g buffer tank expansion tank wire mesh strainer at the pump suction shut off valves 10 vibration compensators are installed to avoid straining the piping and transmitting vibration and noise To assure proper operation of the unit the water volume and flow must be within the operation range as specified in the following table Chiller type Minimum water volume Minimum water flow Maximum water flow EUWA 40K 1700 185 l min 737 l min EUWA 40KX 2400 150 l min 600 l min EUWA 50K 1700 185 l min 737 l min EUWA 50KX 2750 200 l min 715 l min EUWA 60K 2100 230 l min 920 l min EUWA 60KX 3600 235 l min 950 l min EUWA 80K 24001 290 l min 1080 l min EUWA 80KX 300 l min 1165 l min EUWA 100K 3000 370 l min 1160 l min EUWA 100KX 3
76. e C ee 20 Protect the water circuit against freezing ambient conditions or heater tape optional for EUWAB M S K standard for EUWAT or filling up the system with a glycol concentration related to your lowest expected ambient condition The following figure shows the operation range of EUWA 40 120K EUWA 40 50 60 80 100 120KX 50 43 40 5 33 30 20 10 ambient temperature CDB CONTINUOUS OPERATION AREA PULL DOWN AREA Glycol Water optional __ _ standard E ZL os leaving evaporator water temperature C 20 10 0 Protect the watercircuit against freezing ambient conditions or heater tape optional or filling up the system with a glycol concentration related to your lowest expected ambient condition For the EUWAS 40 120 KX the maximum ambient temperature is 38 degr C 2 4 Part 2 Functional Description ESIE98 03 Functional Control 1 3 Thermostat Control Introduction Manual mode versus automatic mode Thermostat steps Display controller The unit is equipped with a thermostat which controls the cooling capacity of the unit Three different controls exist m manual control mode or a control of the capacity by the operator m inlet control mode or a control using the entering evaporator water temperature m outlet control mode or a c
77. e defined user password press and simultaneously Screen Using this menu you can change the password How to change the password Line n Display Description 1 CHANGE PASSWORD screen title 2 NEW PASSWORD the controller requests the new password 3 CONFIRM the controller requests the new password a second time for safety reasons To change the password proceed as follows Step Action 1 Adjust the password using the programming procedure on page 2 23 2 Repeat step 1 confirmation Part 2 Functional Description 2 44 The Digital Controller ESIE98 03 2 42 Part 2 Functional Description ESIE98 03 Part 3 Troubleshooting Introduction The large chillers EUWA 40 120K X are equipped with electronic PCBs These PCBs use the information gained from the input signals to control the output signals If the unit is not performing properly first check the input devices then the PCBs and finally the output devices The chapters in this part are arranged according to this sequence What is in this part This parts contains the following chapters Topic See page 1 Overview of Inputs and Outputs page 3 3 2 Overview of Fault Indications and Safeties page 3 7 3 Checking the Inputs and Outputs page 3 15 4 Troubleshooting page 3 21 Part 3 Troubleshooting 3 1 ESIE98 03 Part 3
78. e side of the compressor Start the rotation compressor for about 5 seconds and check if there is a pressure build up If not change two phases of the power supply 4 10 Part 4 Commissioning and Test Run ESIE98 03 Refrigerant R 134a 3 Refrigerant R 134a 3 1 What Is in This Chapter Introduction As R 134a used for EUWA 40 120KX is not on the market for a very long time we will describe ts components and characteristics in this chapter Overview This chapter covers the following topics Topic See page 3 2 What Is New page 4 12 3 3 Characteristics page 4 13 Part 4 Commissioning and Test Run 4 11 Refrigerant R 134a ESIE98 03 3 2 What Is New Adapted components A Humidity control Mineral oil contamination Handling R 134a The following components of the chillers are adapted to work with R 134a expansion valves dryer material and shape is changed to increase the capacity safety valves material and the set values are changed O ring in order to withstand R 134a pressure switches set values are changed compressor with high pressure 17 bar low pressure 0 5 bar bigger diameter of screw rotor in order to increase the pumping volume different motor windings insulation and adapted oil supply Service tools or equipment in contact with R 22 or mineral oils should not be used on R 134a units and vice versa Use separate manifolds charging uni
79. ecked Freeze up m Water flow too low m Pump operation m Refrigerant shortage m Water flow closed valves and blocked m Operation out of range circuits m Defective thermostat control Flow switch operation Operation condition Blocked parts in the refrigerant system Refrigerant leaks Overcurrent in the compressor m Failure on one of the phases Power supply m Low supply voltage Fuses m Motor overload Mains isolator switch Mains relay contacts Operation condition Compressor windings Current on all 3 phases Reset the overcurrent relay 3 22 Part 3 Troubleshooting ESIE98 03 Troubleshooting Problem Possible causes Items to be checked High pressure switch m Water flow too low in heating m Water temperature too high in heating m Defective condenser fan operation in cooling m Pump operation m Water flow blocked valves m Flow switch operation m Operation condition outdoor air temperature lt 43 C m Dirty or blocked condenser leaving condenser water lt 30 C Operation out of range m State of the condenser clean Flow switch or m Damaged flow switch m Flow switch pump contact m Incorrect pump operation m Pump operation m Incorrect field wiring m Field wiring m Defective control devices m Control devices pump relay Discharge ther mal protector Refrigerant shortage Operation out of range Refrigerant leak Operation condition Fan
80. ee A 1 27 VOIUMO sse ias A EO La be Ee es Ep de eee oe A E het 45 water heat exchangel 21 3sc o A AAA es ek pe a ee ee acd 1 26 wiring diagram cates ks Sas Dee AA 1 41 1 42 Wining layout feats a ath dae caer teate tela RS ne Tanda ES nye asta 1 31 1 40 Index
81. eed Fan step 1 2 Circuit 1 Circuit 2 Ry1 ON Ry2 ON Ry3 OFF M11F M12F M13F M14F M21F M22F M23F M24F EUWA 40 60K X OFF ON ON OFF EUWA 80 120K X OFF ON ON OFF OFF ON ON OFF STEP 3 means no speed Ry1 ON Ry2 ON and Ry3 ON all fans are off Fan step 1 2 3 Part 2 Functional Description 2 7 Functional Control ESIE98 03 Fan control The following procedure explains head pressure control in case of inlet water control procedure start all fans are off m Ta means ambient temperature v m Hp means high pressure M11F M21F starts Ry1 off Y M14F M24F starts Ry2 on head pressure control 1 y time up 180 s time down 20s y NO time up time up 1 time down time down 1 YES Ta gt 17 C NO or Hp gt X bar time down 0 s time down time down 1 Ta lt 15 C and Hp lt Y bar v increase air volume decrease air volume switch on fan switch off fan with X 8 bar for R 134a X 13 5 bar for R 22 Y 5 7 bar for R 134a Y 9 5 bar for R 22 2 8 Part 2 Functional Description ESIE98 03 Functional Control 1 5 Start up Sequence of Fans and Compressor Introduction The following part allows you to understand the different phases of the start up process of the fans related t
82. efrigeration engineer and it must comply with Service tools or equipment coming in contact with R 22 or mineral oils should not be used on R 134a units and vice versa Therefore we strongly advice to have a separate set of manifolds charging units vacuum pump and oil recipients only to be used with R 134a and polyester oils The general procedure for electrical circuit repairs is explained below Step Action 1 Perform the measurements needed to locate the defective parts of the system Switch off the main power supply Check if all capacitor voltages are loaded down Perform the repair according to standard procedures Switch on the power supply 2 3 4 5 6 Verify the proper operation of the replaced part by measurements A All electrical work must be carried out by a licensed electrical engineer and it must comply with all relevant European and national regulations 3 24 Part 3 Troubleshooting ESIE98 03 Troubleshooting 4 4 Changing the PCB Address board for EUWA 80 120K X A Configuration procedure for EUWA 40 120K X Procedure for PCB Changing To change the PCB proceed as follows Step Action 1 Remove the connections of the old PCB 2 Remove the old PCB For the chillers EUWA 80 120K X also remove the address board 3 Place the new PCB in the same way as the old PCB 4 Reconnect the PCB Put als
83. electronic temperature control Options all factory E glycol applications mounted ZH leaving water evaporator 5 C ZL leaving water evaporator 10 C m OP10 anti freeze protection kit evaporator heatertape m OP12 suction stopvalve m OP52 main isolator switch m OP57 ampere amp voltmeter 1 n a Nominal conditions are as follows entering leaving water temperature 12 7 C ambient air temperature 35 C power input is total input compressor control circuit leaving evaporator water temperature from 4 C to 20 C pull down condition to 25 C Part 1 System Outline General Outline ESIE98 03 EUWA 80 120K In the following table you will find the technical specifications of chiller types EUWA 80 120K Nominal cooling input Model EUWA 80K EUWA 100K EUWA 120K Nominal cooling 77 kW 106 kw 115 kw Capacity steps 100 85 70 50 35 20 0 100 85 70 50 35 20 0 100 85 70 50 35 20 0 MAIN COMPONENTS Compressor type speed crankcase heater model x n Evaporator type min water volume system water flow rate nom water pressure drop insulation material Condenser type rows x stages x fin pitch face area nominal air flow discharge fan type n of fans n of motors x output nominal speed Piping connections evap water in outlet evaporator water drain relief device outlet Refrigerant circuit refrigerant type
84. en title 2 STPLENGTH C step length a a4 2 0 ai 1 5 inlet 5 5 outlet 3 STEPDIFFERENCE C step difference b 0 2 5 8 ai 0 5 inlet D e outlet 4 LOADUP 30 s load up time s 5 300 1 180 inlet 30 outlet 4 BUN 30 s loaddown time s 15 300 1 20 inlet 15 outlet Inlet water The figure below shows the inlet water thermostat control thermostat control step number set point 12 0 C a step length b step difference NOoOnRwnmaod inlet water temperature C The figure below shows the outlet water thermostat control setpoint 6 4 7 0 7 6 outlet water temperature C set point 7 0 C al step length 1 a2 step length 2 b1 step difference 1 b2 step difference 2 For more information on thermostat control refer to Thermostat Control on page 2 5 2 28 Part 2 Functional Description ESIE98 03 The Digital Controller Screen 5 optional Screen 6 Screen 7 You can install an optional PCB to control the unit from a PC this feature is under development The BMS Building Management System parameters provide communication between the unit and the PC This screen provides the ability to activate the PC control mode and to modify the BMS settings Line n Display Description sie 1 BMS SETTINGS screen title 2 BMS CONTROL ALLOWED to select PC control mode N 3 UNI ADDRESS used t
85. ering the factory menu on page 3 26 i For glycol units the lower limit of the cooling temperature set point can be adapted in the factory menu The following values apply m inlet 5 C 3 C 2 C 7 C 12 C m outlet 2 C 0 C 5 C 10 C 15 C For more information about these temperatures refer to General overview on page 2 11 Selection between You can select set point 1 or 2 by the remote dual set point switch if installed refer to Field Wiring set point 1 and 2 on page 1 43 Selection between The selection is done in screen 3 of the user settings menu on page 2 27 Use the programming inlet and outlet procedure on page 2 23 control 2 26 Part 2 Functional Description ESIE98 03 The Digital Controller 2 9 Y User Settings Menu Password You need the password to enter this menu The units leave the factory with password 1914 To create your own password refer to page 2 41 Menu description This menu allows a full customizing of the units and provides the following 6 screens Screen n Display Description See page 1 ENTER PASSWORD To enter the password page 2 27 2 REMOTE CONTROL To activate remote control page 2 27 3 CONTROL SETTINGS To adjust and activate manual control mode page 2 27 4 THERMOST SETTINGS To adjust the thermostat settings page 2 28 5 BS SETTINGS To adjust the BMS settings
86. es whether circuit 2 is on YES NO 3 CIRCUIT 2 STAR indicates whether circuit 2 is in star mode YES NO 4 CIRCUIT e DELTA indicates whether circuit 2 is in delta mode YES NO You can find more information in Overview of Inputs and Outputs of EUWA 80 120K X on page 3 5 Screen 10 This screen shows the capacity mode of circuit 1 Line n Display Description Possible settings 1 RELAY OUTPUTS screen title 2 01007 indicates if the 12 capacity valve of N circuit 1 is activated 3 014096 1010963 indicates if the 40 70 capacity valve N of circuit 1 is activated You can find more information in Overview of Inputs and Outputs of EUWA 40 60K X on page 3 4 Screen 11 This screen shows the capacity mode of circuit 2 Line n Display Description Possible settings 1 RELAY GUTPUTS screen title 2 Ce 010 indicates if the 12 capacity valve of 4 N circuit 2 is activated 3 Ce 40 C2 010 indicates if the 40 70 capacity valve Y N of circuit 2 is activated You can find more information in Overview of Inputs and Outputs of EUWA 80 120K X on page 3 5 Part 2 Functional Description 2 39 The Digital Controller ESIE98 03 Screen 12 This screen shows the status of the fan speed relays of circuit 1 Line n Display Description Possible settings 1 RELAY CUTPUTS screen
87. f PCB 2 use _ to change the address for terminal 1 into none TRA NONE 2 Press e 3 In case of PCB 1 use _ to change the parameter private shared of PR or terminal 1 into private In case of PCB 2 use _ to change the parameter private shared of terminal 1 into 4 Press e 5 Use _ to change the address for terminal 2 into none TRMIC NONE Part 3 Troubleshooting 3 25 Troubleshooting ESIE98 03 Step Action Screen 6 Press The parameter private shared shoud be 7 Press 8 Use _ to change the address of terminal 3 into none TRIS NONE 9 Press The parameter private shared shoud be 10 Press E 11 Choose yes using _ YES 12 Press to leave the configuration screen and to enter the read out menu Entering the factory The factory menu is used to set up the identification parameters of the unit according to its PCB To menu enter the factory menu proceed as follows Step Action Result 1 Put on the power supply After a few seconds the user terminal will enter the read out menu Refer to Read out Menu on page 2 24 2 Press and simultaneously for 5 seconds The leds above Pand light up 3 Scroll using _ to go to 1914 4 Press e You have entered the factory menu For more information concerning the controller refer to The Digital Controller on page 2 17
88. f the EUWA 80 120K X PCB A and B Wiring diagram Block Connection symbol Description B7 B2P high pressure transmitter circuit 1 e B8 B1P low pressure transmitter circuit 1 B7 B5P high pressure transmitter circuit 2 Sl B8 B4P low pressure transmitter circuit 2 1 36 Part 1 System Outline ESIE98 03 Wiring Layout Wiring diagram Block Connection Description symbol B1 R5T ambient temperature sensor B2 R3T evaporator inlet water temperature sensor B3 R4T evaporator outlet water temperature sensor B5 B3A field wiring current transmitter circuit 1 A1 current transfo E An optional A meter must be installed J2A refer to Options for EUWA 40 120K on page 1 43 and Options for EUWA 40 120KX on page 1 43 B6 B7V field wiring voltage transmitter V1 i An optional V meter must be installed refer to Options for EUWA 40 120K on page 1 43 and Options for EUWA 40 120KX on page 1 43 B1 B2 B3 B5 B6A field wiring current transmitter circuit 2 J2B A2 current transfo E An optional A meter must be installed refer to Options for EUWA 40 120K on page 1 43 and Options for EUWA 40 120KX on page 1 43 B6 ID6 K2A auxiliary relay compressor thermal protector circuit 1 ID7 S8L S9L flow switch pump contact field wiring van ID8 controller bypass optio
89. he thermostat in automatic mode Refer to Thermostat Control on page 2 5 Part 2 Functional Description Functional Control ESIE98 03 1 6 Freeze up Control Introduction Freeze up prevention Freeze up prevention overview Freeze up protection Freeze up protection overview Freeze up control defines 2 controls m Freeze up prevention m Freeze up protection Freeze up prevention will be activated before the actual freeze up protection in an attempt to prevent the actual protection by loading down the thermostat step In the following table you will find all the characteristics of the freeze up prevention Characteristics Freeze up prevention control device sensor diagram name R3T R4T activation outlet water temperature lt M O W 1K 3 C for standard unit result loaddown of 1 thermostat step reset outlet water temperature gt 4 C result normal mode Freeze up protection is a protection against ice formation in the water circuit at the evaporator outlet It is controlled by the software using the outlet water temperature sensor In the following table you will find all the characteristics of the freeze up protection Characteristics Freeze up protection control device sensor diagram name RST R4T activation outlet water temperature lt M O W 1 5K 2 5 C for standard unit resul
90. high pressure refrigerant circuit 1 in bar and equivalent in C 3 LFI low pressure refrigerant circuit 1 in bar and equivalent in C Subscreen 2 This screen shows information about the pressures of circuit 2 Line n Display Description 1 UNIT SAFETY screen title 2 HPE high pressure refrigerant circuit 2 in bar and equivalent in C 3 LPE low pressure refrigerant circuit 2 in bar and equivalent in C Subscreen 3 This screen shows information about the voltage and compressor current i This screen is available if the optional voltage and current transmitters are installed Line n Display Description 1 UNIT SAFETY screen title 2 VOLTAGE voltage 3 CURRENT Ci compressor current circuit 1 4 CURRENT Ce compressor current circuit 2 Part 3 Troubleshooting Overview of Fault Indications and Safeties ESIE98 03 Subscreen 4 Circuit safety screens Subscreens Subscreen 1 Subscreen 2 This screen shows information about the compressors total running hours and the capacity steps Line n Display Description 1 UNIT SAFETY screen title 2 RUNN HOURS total running hours compressor circuit 1 3 RONN HOURS e total running hours compressor circuit 2 4 ci Ce compressor capacity steps If a circuit safety occurs the following screen is displayed Line n Display Description 1 CIRCUIT 1 2 SAFETY screen title 2 HIGH
91. his screen shows the status of the emergency stop the flow switch and the bypass mode Line n Display Description Possible settings 1 DIGITAL INPUTS screen title 2 EMERGENCY STGP emergency stop button O4 NOT DA 3 FLOWSUITCH flow switch FLOW O4 NG FLOW 4 BYPASS MODE bypass controller YES NO Screen 2 This screen shows the status of the low and high pressure switch and of the reverse phase protector of circuit 1 Line n Display Description Possible settings 1 DIGITAL INPUTS screen title 2 HIGH PR SWITCH I high pressure switch circuit 1 BA NOT DA 3 HIGH PR SWITCH I high pressure switch circuit 1 BA NOT DA 4 REV PH PROT reverse phase protector circuit 1 BK NOT DA You can find more information in Switch box EUWA 40 60K X on page 1 33 and in Main board EUWA 40 120K X on page 1 34 Screen 3 This screen shows the status of the low and high pressure switch and of the reverse phase protector of circuit 2 Line n Display Description Possible settings 1 DIGITAL INPUTS screen title 2 HIGH PR SUNCHE high pressure switch circuit 2 O4 NOT DA 3 HIGH PR SUITCH 2 high pressure switch circuit 2 BA NOT DA 4 REV PH PROT 2 reverse phase protector circuit 2 B4 NOT DA You can find more information in Switch box EUWA 80 120K X on page 1 33 and in Main board EUWA 40 120K X on page 1 34 Part 2 Functional Description 2 37 The Digital Controller ESIE98 03
92. hows the layout of the switch box for the EUWA 40 60K X types EUWA 40 60K X options E transformators power wiring reverse phase K17S contactors main contactors pe fan contactors L field wiring J Switch box The following figure shows the layout of the switch box for the EUWA 80 120K X EUWA 80 120K X m circuit breakers with fuses 7 B3A B7V options transformators L power wiring main contactors r rev phase Al AIA A K7F K8F K9F SSIS 2 fan contactors fan contactors m arii circuit 1 circuit 2 field wiring aux relays Part 1 System Outline 1 33 W
93. illustration below shows you a typical installation outline Some of these installation parts are not outline necessarily included in all the chillers described in this manual CHILLER CHILLER 1 compressor air heat exchanger expansion valve water heat exchanger fan motor refrigerant filter strainer water connections 0 N O oO A WO ND measurement points for temperature PRIMARY WATER CIRCUIT sPRIMARY WATER CIRCUIT 9 10 11 12 13 14 15 16 measurement points for pressure flow switch shut off valves buffer tank water filter water pump drain valve expansion tank SECONDARY WATER CIRCUIT Part 1 System Outline General Outline ESIE98 03 1 20 Part 1 System Outline ESIE98 03 Piping Layout 2 Piping Layout 2 1 What Is in This Chapter Introduction In this chapter we will only explain the internal refrigeration circuit The water piping is considered common practice and is therefore not explained Overview This chapter covers the following topics Topic See page 2 2 Functional Diagram Refrigeration Circuit page 1 22 2 3 Parts Table of the Refrigeration Circuit page 1 26 Part 1 System Outline 1 21 Piping Layout ESIE98 03 2 2 Functional Diagram Refrigeration Circuit Functional diagram The figure below displays the functional diagram of the refrigeration circuit of the chiller types EUWA 40 60K EUWA 40 60K
94. intenance is done Opening the refrigerant circuit may cause a loss of refrigerant or system contamination m Avoid high gas concentrations While the heavy concentration of the refrigerant gas will raise from the floor level good ventilation is a must m Avoid all contact with open fires or hot surfaces By high temperatures the refrigerant gas R 134a may decompose into irritating and poisonous gas Avoid skin and hand contact with the liquid refrigerant and protect your eyes against liquid splashes No maintenance is normally required In case of vibration check the mechanical operation To maintain the oil level Check if If not then the oil level in the sight glass is add oil via the stop valve on the bottom section of the oil approximately 3 4 of the sight glass separator by reducing the air contact to minimum when the compressor is running il Reduce the crankcase pressure to 0 before adding oil or use a hand pump Do not mix different oils The oil used for m compressor types EUWA 40K and EUWA 80K is SUNISO 4GSD 7 5 I m compressor types EUWA 50K EUWA 60K EUWA 100K and EUWA 120K is SUNISO 4GSD 10 1 m compressor types EUWA 40KX and EUWA 80KX is IDEMITSU FVC68D 10 1 m compressor types EUWA 50KX EUWA 60KX EUWA 100KX and EUWA 120KX is IDEMITSU FVC68D 13 1 The compressor suction stop valve if installed and discharge stop valve must be closed during se
95. ion to 25 C Therefore we refer to Engineering Data to obtain this information The data of EUWA 80 120KX were not available when this Service Manual was composed Part 1 System Outline General Outline ESIE98 03 1 4 Outlook Drawing Introduction The diagrams indicate the following important items EUWA 40 60K AIR dimensions service space main components location operation space Below you will find the outlook drawings of the EUWA 40 120K X chiller types The figure below displays the outlook of the chiller type EUWA 40 60K AIR 1110 3980 AIR P AIR 42 6 fixation holes 1012 5 8 x hole for fixation 920 TOESTEL A B D IN OUT EUWAB40K 1515 2030 227 j 03 o3 EUWAB50K 1515 2030 227 I 03 o3 EUWAB60K 1350 2300 260 360 91143 9114 3 BBS AIR AIR DETAIL A 1 10 n EUWAB60K Required space around the unit for service and air intake AIR AIR 4 a Le E JX DETAIL A 1 10 EUWAB40 50K o For a description of the components of the outlook drawings refer to Main components table on page 1 18 Part 1 System Outline ESIE98 03 General Outline Photo
96. ircuit 1 If circuit 2 is de activated due to a fail ure circuit 1 will start up instead When the lead lag control is done automatically the software calculates the difference in operation time between the circuits When this time is higher than the preset lead lag hour value the start sequence of both circuits is swapped The compressor that started first will then start as second The limit values of the lead lag hours are the following m lower limit 100 hours m upper limit 1000 hours m default value 1000 hours This value is important for maintenance purposes It should be set high enough so that both circuits do not require maintenance at the same time and that at least one circuit can remain constantly active The following table gives an explanation of the possible settings Equal start up Description Y yes Both circuits will try to go up in capacity alternatingly N no The leading circuit will try to go to full capacity before the lagging circuit can start up To program the settings of the lead lag control consult screen 6 of the user settings menu on page 2 27 2 12 Part 2 Functional Description ESIE98 03 Functional Control Lead lag working The following table shows the different compressor steps in case of an equal start up or no equal start up If equal start up then If no equal start up then
97. iring Layout ESIE98 03 3 3 Main PCB Layout Main board The figure below shows the main PCB board of the chiller type EUWA 40 120K X EUWA 40 120K X B8 24Vcc B7 a B6 AVSS B5 B4 AVSS B3 B2 AVSS B1 IDCM2 ID10 1D9 1D8 ID7 1D6 IDCM1 1D5 1D4 1D3 ID2 1D1 C1 NO1 C2 NO2 EEEE C3 NO3 C4 NO4 C5 NO5 C12 NO12 i t i 7s The EUWA 80 120K X types contain 2 PCB boards connected through a T device 1 34 Part 1 System Outline ESIE98 03 Wiring Layout Description PCB EUWA 40 60K X The following table explains the different components of the EUWA 40 60K X PCB Block Connection Wiring diagram Description symbol B7 B2P high pressure transmitter J1 B8 B1P low pressure transmitter B1 R5T ambient temperature sensor B2 R3T evaporator inlet water temperature sensor B3 R4T evaporator outlet water temperature sensor B5 B3A field wiring current transmitter A1 current transfo il An optional A meter must be installed J2 refer to Options for EUWA 40 120K on page 1 43 and Options for EUWA 40 120KX on page 1 43 B6 B7V field wiring voltage transmitter V1 i An optional V meter must be installed refer to Options for EUWA 40 120K on page 1 43 and Options for EUWA 40 120KX on page 1 43 ID6 K2A auxiliary relay compres
98. is part offers a systematic approach to test run checks and test values which will guarantee a high quality installation and operation of the units It is therefore recommended to read the chapters in this part with attention What is in this part This parts contains the following chapters Topic See page 1 Pre Test Run Checks page 4 3 2 Test Run amp Operation Data page 4 9 3 Refrigerant R 134a page 4 11 Part 4 Commissioning and Test Run 4 1 ESIE98 03 4 2 Part 4 Commissioning and Test Run ESIE98 03 Pre Test Run Checks 1 Pre Test Run Checks 1 1 What Is in This Chapter Introduction As shown in the table below we have grouped the pre test run checks into three main groups to facilitate the servicing Overview This chapter covers the following topics Topic See page 1 2 General Checks page 4 4 1 3 Water Piping Checks page 4 5 1 4 Electrical Checks page 4 7 Part 4 Commissioning and Test Run 4 3 Pre Test Run Checks ESIE98 03 1 2 General Checks Checklist A checklist of general checks is given below Check if 1 there is external damage all yellow shipping and lifting stays are removed the unit is well supported and or if the foundation is properly done anti vibration pads are required there is a drain possibility for the condens water Oo a BP oO
99. itle 2 AMBIENT ambient temperature 3 RUNN HOURS 1 total running hours compressor circuit 1 4 RONN HOURS 2 total running hours compressor circuit 2 Part 2 Functional Description 2 25 The Digital Controller ESIE98 03 2 8 Set Points Menu Screen 1 password Depending on the settings in screen 7 of the user settings menu on page 2 29 the system may require the password to enter the screens in this menu Line n Display Description 1 ENTER PASSWORD screen title 2 PASSUORD DODD to enter the correct password i The units leave the factory with password 0000 Screen 2 This menu provides the ability to set the inlet and outlet water temperature You can adjust two sets of two temperature set temperature set points Each set contains an inlet and an outlet water temperature set point These points set points will only be active in automatic control mode 7 a PONS fens y Step Line n Display Description Default value Limit value value 1 SETP 1N1 inlet water temp e C 10 to 23 0 C DiE set point 1 2 SETIP INe inlet water temp e C 10 to 23 0 C 01 set point 2 3 SETP QUT outlet water temp 18 4 0 to 16 D C 01 set point 1 4 SETP BUT e outlet water temp 18 C 4 0 to 16 D 01 set point 2 m The actual active setpoint can be consulted in the read out menu refer to page 2 24 m To change the settings refer to Ent
100. kJ m e P to aS 10 K a to sh 10 K o te 40 C 1800 t 40 C gal 1600 tc sc 5 K te s 5 K 1400 4 1200 1000 S 800 r 7 7 7 7 7 7 2 7 7 5 0 5 10 15 20 25 30 bt 5 0 5 10 15 20 25 30 bt Volumetric refrigerating effect Coefficient of performance COP 4 14 Part 4 Commissioning and Test Run ESIE98 03 Part 5 Maintenance Introduction Preventive maintenance should be set up for operation at maximum capacity or to avoid damage The following chapters explain how to or when to maintain the waterchillers What is in this part This part contains the following chapters Topic See page 1 Maintenance page 5 3 Part 5 Maintenance 5 1 ESIE98 03 5 2 Part 5 Maintenance ESIE98 03 Maintenance 1 Maintenance 1 1 What Is in This Chapter Introduction As shown in the table below we have grouped the maintenance in maintenance of the main parts condenser compressor and evaporator and periodical checks Overview This chapter covers the following topics Topic See page 1 2 Maintenance of the Main Parts page 5 4 1 3 Periodical Checks page 5 5 Part 5 Maintenance 5 3 Maintenance ESIE98 03 1 2 Maintenance of the Main Parts Precautions Compressor maintenance A Condenser maintenance A Evaporator maintenance Correct choices and decisions have to be made before any ma
101. lowing steps Step Action 1 Remove the cap from the schroeder valve mounted on the suction side Connect a 1 4 charging line to the schroeder valve Connect the centre line from the manifold to the refrigerant cylinder Air purge the charging lines or open the charging line stop valves Open the stop valve on the charging cylinder Place the charging cylinder on a weighing scale to verify the charge quantity NIOJ oO AJ OJN Open the cylinder valve fully and control the refrigerant flow from the manifold i Head pressure and suction pressure should be stabilized before charging Close the cylinder valve from time to time and verify the sight glass and suction pres sure il If the cylinder pressure drops too low place the cylinder in a bucket of warm water or use a hand held heater to increase the pressure A Never use an open flame and never heat above 50 C Close the charging cylinder 10 Close the charging lines stop valves when the pressure indicated on the manifold is equal to the suction pressure 11 Disconnect the charging line from the schroader valve and replace the cap 12 Check for leaks Part 3 Troubleshooting 3 33 Troubleshooting ESIE98 03 3 34 Part 3 Troubleshooting ESIE98 03 Part 4 Commissioning and Test Run Introduction Commissioning and test run are well known practices in service engineering Th
102. mber set point 12 0 C a step length a b b step difference NO fh WM O inlet water temperature C Outlet water The figure below clarifies the outlet water temperature control in equal start up temperature control setpoint set point 7 0 C ai step length 1 a2 step length 2 b1 step difference 1 b2 step difference 2 6 0 5 6 4 7 0 7 6 7890 outlet water temperature C In general the parameters a1 and b1 are used In case a compressor has to start up or shut down a2 and b2 are used In the following table you will find the limit and default values of a1 a2 b1 and b2 Thermostat parameters Lower limit Upper limit Step Default Step length 1 a11 05 g a 0 5 Step length 2 a2 al 00 al 00 0 1 al 00 Step difference 1 b12 D e 0 8 Di Qe Step difference 2 b22 D e D Di ue 1 Parameter a1 is the set up as parameter a in the software 2 Parameters b1 and b2 are always equal and are set up as parameter b in the software 2 6 Part 2 Functional Description ESIE98 03 Functional Control 1 4 Fan Speed Control after Start up Head Pressure Control Functional The chiller types EUWA 40 120K X are equipped with a fan control to assure a minimum high description pressure when the ambient temperature is low In the wiring diagram this head pressure control is positioned in block J22 for EUWA 40 60K X and J22A and J22B f
103. n 2 To consult additional unit information page 2 36 Part 2 Functional Description 2 21 The Digital Controller ESIE98 03 Menu key Access Screen n Task description See page Input output direct Screen 1 To read the status of the emergency stop the flow switch page 2 37 and the bypass mode Screen 2 To read the status of the low and high pressure switch and page 2 37 of the reverse phase protector of circuit 1 Screen 3 To read the status of the low and high pressure switch and page 2 37 of the reverse phase protector of circuit 22 Screen 4 To read the status of the overcurrent relay the discharge page 2 38 thermal protector and the compressor thermal protector of circuit 1 Screen 5 To read the status of the overcurrent relay the discharge page 2 38 thermal protector and the compressor thermal protector of circuit 22 Screen 6 To read the status of the remote dual set point switch and page 2 38 the remote start stop Screen 7 To read the status of the remote compressor disable page 2 38 switches Screen 8 To read the status of the power relays of circuit 1 page 2 39 Screen9 To read the status of the power relays of circuit 2 page 2 39 Screen 10 To read the capacity mode of circuit 1 page 2 39 Screen 11 To read the capacity mode of circuit 22 page 2 39 Screen 12 To read the status of the fan speed relays of circuit
104. nal ID9 10S dual setpoint selection switch field wiring ID10 S6S field wiring remote start stop switch ID6 K5A auxiliary relay compressor thermal protector circuit 2 ID7 11S switch that disables circuit 1 when closed field wiring J3B ID8 12S field wiring switch that disables circuit 2 when closed ID9 ID10 Part 1 System Outline 1 37 Wiring Layout ESIE98 03 Wiring diagram Block Connection Description symbol 1D1 S1PH high pressure switch circuit 1 ID2 S14PH high pressure switch circuit 2 J4A ID3 RiP reverse phase protector circuit 1 ID4 K17S overcurrent relay circuit 1 ID5 K3A auxiliary relay for discharge thermal protector circuit 1 1D1 S2PH high pressure switch circuit 2 ID2 S15PH high pressure switch circuit 2 J4B ID3 R2P reverse phase protector circuit 2 ID4 K18S overcurrent relay circuit 2 ID5 K6A auxiliary relay for discharge thermal protector circuit 2 C1 NO1 K3M star contactor circuit 1 J5A C2 NO2 K2M delta contactor circuit 1 C1 NO1 K6M star contactor circuit 2 J5B C2 NO2 K5M delta contactor circuit 2 C3 NO3 K1M compressor 1 on C4 NO4 H1P field wiring pump contact and general operation indication C5 NO5 H2P field wiring alarm indication J6A C12 NO12 E3H field wiring evaporator heater i An optional heatertape must be installed refer t
105. nals on field rail 1 2 71 72 73 74 75 76 77 78 79 als y frye OFF OFF 80 81 82 83 84 85 86 The numbers refer to the items in the terminal connections ON operation 230 V3 24 V OFF no operation FL flow switch P pump contact 1 44 Part 1 System Outline ESIE98 03 Wiring Layout EUWA 80 120K X location EUWA 80 120K X terminal connections location in switchbox field wiring location in wiring diagram L field wiring examples EUWA 80 120K X EUWA 80 120K X ltem Code Description Terminals Remarks 1 L1 L2 L3 PE power supply to unit L1 L2 L3 PE 2 S13S mains isolator switch L1 L2 L3 3 3 10S dual set point switch 76 78 4 S6S remote start stop 76 79 1 3 5 S8L S9L flow switch pump contact 75 77 2 6 118 enable disable circuit 1 84 85 7 128 enable disable circuit 2 84 86 8 H2P alarm indication 71 72 2 9 H3P operation compressor 1 indication 80 81 2 10 H4P operation compressor 2 indication 82 83 2 11 H1P general operation indication and pump contact 73 74 2 12 E3H evaporator heater 1 2 3 Remarks 1 These require programming see page 2 27
106. nctional Control 1 1 What Is in This Chapter Introduction This chapter will give more detailed information on the functions used to control the system Understanding these functions is vital when diagnosing a malfunction which is related to the functional control Overview This chapter covers the following topics Topic See page 1 2 Operation Range page 2 4 1 3 Thermostat Control page 2 5 1 4 Fan Speed Control after Start up Head Pressure Control page 2 7 1 5 Start up Sequence of Fans and Compressor page 2 9 1 6 Freeze up Control page 2 10 1 7 Lead lag Control only for EUWA 80 120K X page 2 12 1 8 Discharge Temperature Protector page 2 14 1 9 Heatertape optional page 2 15 1 10 Head Pressure Setback page 2 16 Part 2 Functional Description 2 3 Functional Control ESIE98 03 1 2 Operation range EUWA 40 120K Operation range EUWA 40 120KX Operation Range The following figure shows the operation range of EUWA 40 120K EUWA 40 50 60 80 100 120K ambient temperature CDB 50 43 p gt 40 AS NE E he 39 i 36 A A PA O 30 l l l w l o 20 l CONTINUOUS OPERATION PULL DOWN 10 AREA AREA SS 0 10 PE eae ee Glycol Water A 20 optional _ _ standard leaving evaporator a ZH water temperatur
107. nd the capacity steps Line n Display Description 1 Ce HISTORY XXX screen title 2 RUNN HOURS total running hours compressor circuit 1 3 RONN HOURS 2 total running hours compressor circuit 2 4 ci Ce compressor capacity steps Part 2 Functional Description 2 35 The Digital Controller ESIE98 03 2 12 O Info Menu Additional unit Using this menu you can consult additional information about the unit There are two screens information Screen 1 This screen shows the unit information Line n Display Description 1 UNIT INFORMATION screen title 2 UNMNANE the unit name 3 REFRIGERANT the used refrigerant 4 MANUFACT NR the manufacturing serial number Screen 2 This screen shows extra unit information Line n Display Description 1 UNIT INFORMATION screen title 2 SOFTUARE VERSION the controller s software version 3 not used 4 not used 2 36 Part 2 Functional Description ESIE98 03 The Digital Controller 2 13 Input Output Menu Reading the status Using this menu you can read the status of the digital inputs and the status of the relay outputs of inputs and m Screens 1 to 7 provide status information of the digital inputs outputs m Screens 8 to 14 provide status information of the relay outputs Screen 1 T
108. nlet outlet water temperature circuit 1 4 ANB ambient temperature circuit 1 Subscreen 2 1 This screen shows information about the pressures of circuit 1 Line n Display Description 1 CLHISTORY XXX screen title 2 HP i high pressure refrigerant circuit 1 in bar and equivalent in C 3 LP low pressure refrigerant circuit 1 in bar and equivalent in C Subscreen 2 2 This screen shows information about the pressures of circuit 2 Line n Display Description 1 CLHISTORY XXX screen title 2 HPE high pressure refrigerant circuit 2 in bar and equivalent in C 3 LPe low pressure refrigerant circuit 2 in bar and equivalent in C Subscreen 2 3 This screen shows information about the voltage and compressor current i This screen is available if optional voltage and current transmitters are installed Line n Display Description 1 CLHISTORY XXX screen title 2 VOLTAGE voltage 3 CURRENT Ci compressor current circuit 1 4 CURRENT Ce compressor current circuit 2 Subscreen 2 4 This screen shows information about the total running hours of the compressors and the capacity steps Line n Display Description 1 CI HISTOR XXX screen title 2 RUNN HOURS 1 total running hours compressor circuit 1 3 RONN HOURS 2 total running hours compressor circuit 2 4 ci Ce compressor capacity steps 2 34 Part 2 Functional Description ESIE98 03 The Digital Co
109. ntroller Screen 3 Subscreen 3 1 Subscreen 3 2 Subscreen 3 3 Subscreen 3 4 This screen shows the circuit 2 history Line n Display Description 1 Ce HISTORY XXX x the total number of circuit 2 shutdowns 2 HIGH PRESSURE SUITCH activated circuit 2 safety 3 INL GUTL inlet outlet water temperature circuit 2 4 ANB ambient temperature circuit 2 This screen shows information about the pressures of circuit 1 Line n Display Description 1 Ce HISTORY XXX screen title 2 HP high pressure refrigerant circuit 1 in bar and equivalent in C 3 LP low pressure refrigerant circuit 1 in bar and equivalent in C This screen shows information about the pressures of circuit 2 Line n Display Description 1 Ce HISTORY XXX screen title 2 HPE high pressure refrigerant circuit 2 in bar and equivalent in C 3 LPE low pressure refrigerant circuit 2 in bar and equivalent in C This screen shows information about the voltage and compressor current This screen is available if optional voltage and current transmitters are installed Line n Display Description 1 Ce HISTORY XXX screen title 2 VOLTAGE voltage 3 CURRENT Ci compressor current circuit 1 4 CURRENT Ce compressor current circuit 2 This screen shows information about the total running hours of the compressors a
110. o Options for EUWA 40 120K on page 1 43 and Options for EUWA 40 120KX on page 1 43 C3 NO3 K4M compressor 2 on C4 NO4 J6B C5 NO5 C12 NO12 J17A G GO power supply controller J17B G GO power supply controller 1D11 ID11R S5E emergency stop button J21A 1D12 1D12R ID11 ID11R J21B 1D12 1D12R 1 38 Part 1 System Outline ESIE98 03 Wiring Layout Block Connection boli ai Description C9 NO9 NC9 K7F fan step 1 contactor circuit 1 J22A C10 NO10 NC10 K8F fan step 2 contactor circuit 1 C11 NO11 NC11 K9F fan step 3 contactor circuit 1 C9 NO9 NC9 K10F fan step 1 contactor circuit 2 J22B C10 NO10 NC10 K11F fan step 2 contactor circuit 2 C11 NO11 NC11 K12F fan step 3 contactor circuit 2 C6 NO6 Y11S 12 capacity step for compressor circuit 1 J24A C8 NO8 Y12S 40 capacity step for compressor circuit 1 C13 NO13 Y13S 70 capacity step for compressor circuit 1 C6 NO6 Y11S 12 capacity step for compressor circuit 2 J24B C8 NO8 Y12S 40 capacity step for compressor circuit 2 C13 NO13 Y13S 70 capacity step for compressor circuit 2 T device between EUWA 80 120K X contain 2 PCB boards A and B that are connected through a T device This PCB A and PCB B device enables contact with the address cards on the PCB boards The following figure shows the connection group
111. o address the unit if more than one 80 99 unit is connected to the PC 4 PROTOCOL indicates the communication protocol CAREL This screen will only be displayed if the optional BMS PCB is installed under development This screen provides the ability to adjust the lead lag settings Lead lag control is only available on chiller types EUWA 80 120K X Line n Display Description Possible settings 1 LEAD LAG SETTINGS screen title 2 LEAD LAG MODE The controller decides whether circuit 1 AUTOMATIC or circuit 2 starts up first Circuit 1 starts up before circuit 2 If Ci gt Ce manual circuit 1 is de activated due to a failure circuit 2 will start up instead Circuit 2 starts up before circuit 1 If Ce gt Li manual circuit 2 is de activated due to a failure circuit 1 will start up instead 3 LEAD LAG HOURS The maximum difference between the lower limit 108 4 running hours of both circuits upper limit 1008 H in automatic mode default value 1080 H 4 EQUAL STARTUP Both circuits will try to go up in capacity 3 yes alternatingly The leading circuit will try to go to full no capacity before the lagging circuit starts up For a functional description of the lead lag control refer to Lead lag Control only for EUWA 80 120K X on page 2 12 This screen provides the ability to assign password protection to the set point menu Line n Display
112. o replace a filter core replacement Step Action 1 Close the inlet stop valve on the filter dryer 2 Operate the compressor until the unit pumps down to 1 5 bar 3 Close the outlet stop valve on the filter dryer 4 Remove the remaining pressure via the 3 8 charging valve on the filter body by connecting the discharge of the pump out unit to the condenser side of the unit High pressure service point This step is also named compartimentation i Do not stop the liquid injection to the compressor during pump down This will cause overheating and compressor damage 5 Warm up the filter body with a hand hold heater before opening the filter dryer to avoid moisture deposits within the filter body and liquid line 6 Prepare the filter cover gasket before opening the new filter core container in order to keep air exposure to a strict minimum i The compressor suction stop valve if installed and discharge stop valve must be closed during service or repair to avoid moisture Part 3 Troubleshooting 3 29 Troubleshooting ESIE98 03 4 7 Oil Changing Procedures Oil draining When the oil has degraded or the moisture level becomes to high the oil has to be drained To drain oil proceed as follows Step Action 1 Pump the unit down to 1 5 bar low pressure 2 Using compartimation lower the suction pressure to a slight positive pressure in order to force the oil into a receptacle i Com
113. o the actual cooling capacity of the unit i When a circuit is in a high pressure setback the indication 70 will be flashing A high pressure setback is a loaddown from 100 to 70 caused by a too high pressure Screen 3 This screen shows information about the pressures of circuit 1 Line n Display Description 1 ACTUAL PRESSURES screen title 2 HP high pressure refrigerant circuit 1 in bar and equivalent in C 3 LP low pressure refrigerant circuit 1 in bar and equivalent in C 2 24 Part 2 Functional Description ESIE98 03 The Digital Controller Screen 4 This screen shows information about the pressures of circuit 2 only for EUWA 80 120K X Line n Display Description 1 ACTUAL PRESSURES screen title 2 HPE high pressure refrigerant circuit 2 in bar and equivalent in C 3 LPE low pressure refrigerant circuit 2 in bar and equivalent in C Screen 5 This screen shows information about the voltage and compressor current il This screen is available if optional voltage and current transmitters are installed Line n Display Description 1 VOLTAGE CURRENT screen title 2 VOLTAGE voltage 3 CURRENT Ci compressor current circuit 1 4 CURRENT Ce compressor current circuit 2 Screen 6 This screen shows information about the ambient temperature and the total running hours of the compressors Line n Display Description 1 EXTRA READOUT screen t
114. o the address board back for the chillers EUWA 80 120K X The address boards on the PCBs indicate the addresses of the PCBs of 2 circuits From factory the PCB on top refers to circuit 2 and the PCB beneath refers to circuit 1 m Make sure that the dip switches are correctly set Refer to T device between PCB A and PCB B on page 1 39 m Always make sure that PCB 1 is completely configured before PCB 2 If this is not taken into account this can result in a communication problem between PCB 1 and PCB 2 To start configuration proceed as follows Step Action Result 1 Put on the power supply Nothing will appear on the screen because no configuration has been made 2 Press and After a few seconds the user terminal will enter a screen in simultaneously for 5 which ARCANOS TERMINAL ADR 3 1 0 BOARD ADR in case of PCB 1 or in case of PCB 2 If the values on the screen are different from the values above you can change them using _ 3 Press E You have entered the terminal configuration screen 4 Press to continue For more information concerning the controller refer to The Digital Controller on page 2 17 Terminal configuration of To continue the configuration proceed as follows EUWA 40 120K X Step Action Screen 1 In case of PCB 1 use _ to change the address for terminal 1 into 3 In TRA OF or case o
115. o the compressor il This explanation is based on the types EUWA 40 60K X Fans location The following illustration shows the position of the fans according to the compressor Im1F Dni J Mi3F mar compressor 9 switchbox Start up of the The following diagram explains the start up procedure of the compressor and fans in a time frame compressor The total start up period is 140 s in case of manual mode or 200 s in case of automatic mode fan phase 2 phase 3 start up procedure phase 1 gt fan M12F M13F fan M14F fan M11F A 100 A 70 A4 A A O ON A12 is Aims FR _ a time 5s 15s fixed time 120s or thermostat load up time 180s depending on head pressure controle Phase Description Initial Initially the compressor starts up in star wiring and only fan M11F operates Phase At the beginning of phase 1 the compressor start up turns from star to delta The 1 capacity remains 12 This action also starts fan M14F Phase From phase 2 you can put the fans on and off according to the settings in manual mode 2 or according to the head pressure control in automatic mode Refer to Fan Speed Con trol after Start up Head Pressure Control on page 2 7 The compressor remains at 40 Phase From phase 3 the compressor turns in the desired capacity steps according to the 3 settings in manual mode or according to t
116. oils are very hygrocopic use containers corresponding to the required oil charge quantity 3 30 Part 3 Troubleshooting ESIE98 03 Troubleshooting Illustration The following photos shows the content of the oil separator discharge from the screw side first oil separation unloader mechanism oil filter discharge side of the compressor cover of oil separator second oil separation Part 3 Troubleshooting 3 31 Troubleshooting ESIE98 03 4 8 Refrigerant Charging Refrigerant leak For refrigerant leak detection use an electronic leak detector sensitive for R 134a or for R 22 detection If then the unit is under the pressure limit 1 look for oily spots on fittings and flanges 2 wipe clean 3 verify at a later stage Liquid charging This method is customary for larger systems Therefore a 3 8 charging valve is provided on the filter dryer body so that the refrigerant can be added while the system is operating Step Action 1 Connect the refrigerant to the 3 8 charging port Use a short 3 8 charging line to minimise contamination or via a dryer if indicated The cylinder should be upside down if it does not have a liquid vapour valve Observe the pressure gauge Purge the charging line or open the charging line stop valves Tighten the connections Open the cylinder valve and check for leaks Oo oa AJ wo NY
117. ol GOSCHPIION A A ALE ee Oe A eee eee 2 27 SIart SlOPiss fabs tee A A A A EE eats armies 2 27 remote dual set point switch 20 0 cette 2 26 repair GIS CHI Cal eCHCUIES Set ican a se ad he de Sh le E ea a ola ede A atten oe 3 24 PFOCOCUIC 8 50 6 fs te ae gee is Ma A at aes Utes 3 24 LOTO AO CIC a a ia ceca 3 24 S safety AAA A E 2 20 3 12 OVEIVIOW iii tit ducts A id A Be Sais E A al AA a io 3 12 nit SAO cit a taa as 2 20 3 12 SONS E A A A AR AA AA AS Gun la ye A A AA adler A okey 3 4 3 5 sensors ambient temperature SENSO 6 eee ee een eee ene e ene ee 1 27 controllet SENSOFS ected a ae tate Qn does a tate are Pedder kane aden pt ds eet 3 17 YPO ive Ye bea ee ae eee wee tote oe Saad eed dee dant E Sea be dee 3 16 water temperature Sensor 2 tet e ee 1 27 Set HOMS MENUA ha a A Tae ae hehe lade ie Ned eT en Aa 2 21 2 26 SIDO LILA Siua tcc sts ded bctee ee cote A vd kad altace a ia o 1 27 SOMWANE TIMERS 0 ich te e di Tr Aa aaa aa aia 2 30 start Up SOQUENCO cocida Toke eee ak in ok ae ti Keke ee bed 2 9 switch box AVOUT eee ale awn case mtb alae alg wee erat alee line wh Delve ai na ate 1 32 switch box 1 33 ESIE97 02 General index T TEC tl EE AAE AA E OE et ole E A E AESA E cde A E Be 1 39 technical specifications saa aa a n a eee 1 4 1 6 1 8 1 10 temperature SENSOMS wk eters A A td a A aa eee wae 3 16 temperature Settings erse cc ces ase een eae reve A Dea Dee a A A OE A a aa A Wiat
118. ompressor current circuit 2 Subscreen 4 This screen shows information about the total running hours of the compressors and the capacity steps Line n Display Description 1 CIRCUIT 1 2 SAFETY screen title 2 RONN HOURS 1 total running hours compressor circuit 1 3 RONN HOURS 2 total running hours compressor circuit 2 4 ci te compressor capacity steps Part 3 Troubleshooting 3 11 Overview of Fault Indications and Safeties ESIE98 03 2 3 Safeties Overview Unit safeties Alarm description Alarm indication Activation Reset ae Device emergency stop EMERGENCY STOP push the emergency unlock the button and S5E contact button start the unit flow switch or pump FLOWSUITCH no flow for 5 seconds manual software reset S8L contact contact ACTIVATED GR NOT closed on flow freeze up FREEZE UP outlet water temperature manual software reset R4T NTC sensor protection lt 2 5 C refer to page 2 10 Circuit safeties wee Peat tt Wiring Alarm description Alarm indication Activation Reset code Device high pressure HIGH PRESSURE discharge pressure gt m manual software S1PH switch on off switch SUITEH 1 2 17 bar R 134a reset S2PH contact discharge pressure gt m reset on the switch eh 25 bar R 22 low pressure LOU PRESSURE 1 2 lt 0 5 bar manual software reset B1P low pres transmitter sure transmitter discharge thermal DISCHARGE discharge
119. ontrol using the leaving evaporator water temperature The following table shows the difference between manual and automatic mode If then there is manual capacity control fixed capacity step control no thermostat control automatic control an inlet or outlet thermostat control The following table shows the maximum number of thermostat steps for each chiller type Chiller type Maximum number of thermostat steps EUWA 40 60K X 3 EUWA 80 120K X 7 when equal start up or no equal start up For more information about equal start up refer to Lead lag Control only for EUWA 80 120K X on page 2 12 Screen 3 of the user settings menu provides the ability to modify the thermostat parameters Refer to the user settings menu on page 2 27 E A z ii Lower Upper Line n Display Description limit limit Step Default 1 THERN SETTINGS screen title 2 STPLENGTH C step length a ia 2 0 01 1 5 inlet 3 6 outlet 3 STEPDIFFERENCE C step difference b 50 2 8 01 0 5 inlet D e outlet 4 LOADUP load up time s 15 300 1 180 inlet 30 outlet 5 DUN loaddown time s 15 300 1 20 inlet 15 outlet Part 2 Functional Description 2 5 Functional Control ESIE98 03 Inlet water The figure below clarifies the inlet water temperature control temperature control step nu
120. or EUWA 80 120K X The following features enable the fan speed control m During normal operation or when no signal is sent all fans rotate at high speed m During head pressure control a set of fan steps is executed in order to switch off the corresponding fan motors This execution enables the control of the condensing pressure Overview fan steps The following table clarifies the different fan steps Fan step Action for EUWA 40 60K X Action for EUWA 80 120K X 1 Ry1 controlling NC9 is energized in Ry1 controlling NC9 is energized in order to switch off fan motor M11F order to switch off M11F and M21F 2 Ry2 controlling NC10 is energized in Ry2 controlling NC10 is energized in order to switch off fan motor M14F order to switch off M14F and M24F 3 Ry3 controlling NC11 is energized in Ry3 controlling NC11 is energized in order to switch off M12F and M13F order to switch off M12F M13F M22F and M23F Fan sequence In the tables below you will find an overview of the 4 steps of relay and fan STEP 0 means high speed Ry1 OFF Ry2 OFF and Ry3 OFF all fans are on standard STEP 1 means medium speed Fan step 1 Circuit 1 Circuit 2 Ry1 ON Ry2 OFF Ry3 OFF M11F M12F M13F M14F M21F M22F M23F M24F EUWA 40 60K X OFF ON ON ON EUWA 80 120K X OFF ON ON ON OFF ON ON ON STEP 2 means low sp
121. partimentation Pumping of the refrigerant from low to high pressure using a pump out unit 3 Remove the oil out of the compressor by untighing the large hexagon nut located under the sight glass Oil filter cleaning The following procedure explains how to clean the oil filter Step Action 1 Follow the oil drain procedure to recover the refrigerant and to drain the oil 2 Remove the cover of the oil separator 3 Remove the oil filter for cleaning or changing 4 Clean the oil separator with an ozone friendly cleaning solvent 5 Mount the filter again 6 Reassemble the oil seperator Oil charging After used oil has been drained a fresh oil charge is required This is normally the same amount as was removed and is visually less than the initial charge because a small part of the oil still remains in some of the parts The equipment to charge is a vacuum pump and a charging line fitted with a shut off valve A pressure gauge can be useful The purpose is to get clean oil into a contaminent free system Therefore proceed as follows Step Action 1 Pull a complete vacuum on the compressor before charging new oil 2 Close the shut off valve 3 Stop the vacuum pump 4 Connect the oil container via a charging hose to the oil charge valve 5 Purge the oil charge hose and open the oil drain valve il The oil container should only be opened before charging Since ester
122. r covers the following topics Topic See page 4 2 Items to Be Checked page 3 22 4 3 General Repair Procedures page 3 24 4 4 Procedure for PCB Changing page 3 25 4 5 Pump Down page 3 28 4 6 Filter Procedure page 3 29 4 7 Oil Changing Procedures page 3 30 4 8 Refrigerant Charging page 3 32 Part 3 Troubleshooting 3 21 Troubleshooting ESIE98 03 4 2 Items to Be Checked Introduction In the tables below the most frequent failures and their corrective action are explained Use these tables when the unit or a circuit does not start No malfunction The unit does not start and there is no malfunction indication indication Possible causes Items to be checked Power supply problem m Loose or broken connections m Main supply m Blown fuses due to short circuit m Control system supply m Defective transformer m PCB supply The unit is not switched on m Check the remote start stop setup and correct if setup incorrectly m Check the field wiring in case of remote control One of the timers is still active Check the timers overview in this manual or in the controller and wait until all timers have elapsed The unit is programmed incorrectly Check the settings EY The compressor step in manual mode control should not be set to 0 Malfunction The unit does not start because of a malfunction indication Problem Possible causes Items to be ch
123. ration range EUWA 40 120K page 2 4 Operation range EUWA 40 120KX page 2 4 Outlet water temperature control page 2 6 and page 2 28 Outlook EUWA 40 60K page 1 14 Appendix B Drawings ESIE98 03 Call outs See page Outlook EUWA 80 120K page 1 15 Outlook EUWA 40 60KX page 1 16 Outlook EUWA 80 120KX page 1 17 Output route page 3 18 PCB page 1 34 Programming procedure page 2 23 Screen detail of the digital controller page 2 18 Start up of the compressor page 2 9 Switch box EUWA 40 60K X page 1 33 Switch box EUWA 80 120K X page 1 33 T device between PCB A and PCB B page 1 39 Typical installation outline page 1 19 Volumetric refrigerating effect R 134a versus R 12 page 4 14 Wiring diagram EUWA 40 60K X page 1 41 Wiring diagram EUWA 80 120K X page 1 42 Appendix B Drawings ESIE97 02 index General index A address A A AE 3 25 air Neat EXCHANGER eiii a he ary ae dae a AA 1 26 alarm circuit alam ii AA A ean SR Rite Ba ead iia dyed 2 20 3 8 general asii de LAR gle cee Meter dat eed ad did La e E dando A TA 2 20 A pe a ea NN 2 20 3 8 ambient temperature Sensor 6 an E EE eee eee ee ee aE EA AAE 1 27 AN es na eee A ed E we wesw ele cd eel E A eee a AUO WENA EA Bs ade 3 4 C calculation of the minimum water volume 1 2 0 0 ccc eee 4 6 CHANGE PAM ja wry ts ii te e li toi tice 2 23 change pa
124. rvice to avoid moisture level increase A fouled condenser indicating an abnormally high condensing pressure can result in an increasing power consumption and trip outs Verify the saturated condenser pressure temperature difference to the leaving air temperature If the difference is more than 15 C clean the outside surface of the condenser by rinsing the coil surface with low pressure fresh water in order to remove possible salt deposits Do not damage the fins when cleaning m Inspect the evaporator tubes after the first operating season This condition indicates the required frequency of cleaning and also whether water treatment is needed in the chilled water circuit m Check the air plugs and drain plugs to prevent or detect water leakage 5 4 Part 5 Maintenance ESIE98 03 Maintenance 1 3 Electrical checks Refrigerant checks Fan check Water checks Noise checks Periodical Checks Inspection checks and actions Remarks Check that all electrical wiring are properly connected and securely tightened Check the electrical components on damage or loss Check if the power supply corresponds with the identification label of the unit Check the operation of the circuit breaker and the earth leak detector of the local supply panel Inspection checks and actions Remarks Check the refrigerant circuit m lf
125. rview of Inputs and Outputs of EUWA 40 60K X on page 3 4 and in Overview of Inputs and Outputs of EUWA 80 120K X on page 3 5 Screen 7 This screen shows the status of the remote compressor disable switches i The compressor disable switches are only available on chiller types EUWA 80 120K X Line n Display Description Possible settings 1 DIGITAL INPUTS screen title 2 EN DISABLE 1 remote compressor disable switch circuit 1 ENABLE DISABLE 3 EN DISABLE 2 remote compressor disable switch circuit 2 ENABLE DISABLE You can find more information in Overview of Inputs and Outputs of EUWA 80 120K X on page 3 5 2 38 Part 2 Functional Description ESIE98 03 The Digital Controller Screen 8 This screen shows the status of the power relays of circuit 1 Line n Display Description Possible settings 1 RELAY GUTPUTS screen title 2 CIRCUIT 1 ON indicates whether circuit 1 is on YES NO 3 CIRCUIT 1 STAR indicates whether circuit 1 is in star mode YES NO 4 CIRCUIT DELTA indicates whether circuit 1 is in delta mode YES NO You can find more information in Overview of Inputs and Outputs of EUWA 40 60K X on page 3 4 Screen 9 This screen shows the status of the power relays of circuit 2 Line n Display Description Possible settings 1 RELAY GUTPUTS screen title 2 CIRCUIT 2 ON indicat
126. s See nies aes els SE Maa cea Ge E Gales 4 12 general usi ewe hee es A Peay cade bia Mee pe theta da weeds els 3 30 Operation datas fcc wa O eas Hehe 4 9 op ration TANTO ii A a duvets abate band ine ates 2 4 OPS A A A Death daly A 1 43 outlet water temperature control 6 0 ete eee 2 6 QUO 2 ccd See ee eee ea Ee Re ele deed ob Ged og eae eae is 1 14 1 15 1 16 1 17 OVEICUITFEN ties ido pats ache Rag Dieta ara eet dood aa aa ee ew Ba A eae ahaa eee 3 19 overview of inputs outputs ke ee ea ha See oe eek A een eee ee 3 3 P parameters NOW tO changa s Tracee aha e A AI E a A dee tvs 2 23 MOW OSCE A aana d aa Ea aaa A ae ie E AT oa a 2 23 password Change passworde seresa ae a aaea anes w E ok ative ak depen a E coe GE are ete aes 2 41 SOPA A whale dete a A dabei welt Ra 2 29 password MENUS A AAA ee A tee al ees 2 22 2 41 PCB CMAN GUNG sites ies Treen haat LCS caved wate TA A Seah gaat deat ahah iy ieee Behl 3 25 PODA Beran Bee EEEE eres tomate ee ated oe coa EASTA 1 34 Index ESIE97 02 General index piping layouts pes IN EN 1 21 A oS are A 3 19 Pre teSt run CHECKS e cc a lace Weed dig eae aad iaa 4 3 procedure TAR COMUUO cede E canaries tte Mesh ements dan dian toe ORAR 2 8 programming procedure lt e s ees ae he pi a needa Wie ke pesca aie be eee weed 2 23 PFOGFAMMING a A ened aaah aia A RAM mae oR al wre endear ise eae oe 2 23 PUMP WM ss cece ra a Sowa len Gate ene at ee bea A a a als 3 28 R
127. scharge thermal protector K2A J4 ID6 auxiliary relay compressor thermal protector contact S1PH J4 ID1 high pressure switch 1 S14PH J3 ID2 high pressure switch 2 S8L S9L J3 ID7 flow switch pump contact e J4 ID8 controller bypass optional 10S J4 1D9 dual set point selection switch S6S J43 110 remote start stop switch S5E J21 ID11 emergency stop button digital output contact K3M J5 C1 star contactor K2M J5 C2 delta contactor K1M J6 C3 compressor on H1P J6 C4 general operation and pump contact H2P J6 C5 alarm indication E3H J6 C12 evaporator heater transducer Y11S J24 C6 12 capacity step compressor Y12S J24 C8 40 capacity step compressor Y13S J24 C13 70 capacity step compressor K7F J22 C9 fan control 1 contactor K8F J22 C10 fan control 2 contactor K9OF J22 C11 fan control 3 contactor Part 3 Troubleshooting ESIE98 03 Overview of Inputs and Outputs 1 3 Overview of Inputs and Outputs of EUWA 80 120K X The following table describes the relation between the wiring diagram symbols and the wiring connections of chiller types EUWA 80 120K X We refer to the wiring diagram and the PCB layout to find the exact location on both wiring diagram and switch box Wiring diagram Wiring connec Type Detail symbol tion terminal Description analog input sensor R5T J2A B1 ambient temperature sensor R3T J2A B2 evaporator inlet water temperature sensor R4T J2A B3 evaporator outlet water
128. se then you should measure the relevant signals using the schematic input route shown above The output is generated from the PCB If a device does not operate you should find the relevant output signal from the PCB in order to decide whether the PCB or the device needs replacement The output route is shown in the block diagram below PCB OUTPUT CONTROL RELAY DEVICE voltage free contact 230 V supply e g fan valve Part 3 Troubleshooting ESIE98 03 Checking the Inputs and Outputs 3 4 Checking the Power Supply and Fuses Overview PCBs Overview fuses and overcurrent EUWA 40 60K X Overview fuses and overcurrent The following overview shows the circuits the voltages and their fuse codes Circuit main supply main circuit control circuit fans relays control circuit digital heater circuit Wiring code L1 L2 L3 L1 L2 L3 TR1 prim TR1 sec TR3 sec OP10 Type voltage 3 phases 400 V AC 3 phases 400 V AC 2 phase 400 V AC 1 phase 230 V AC 1 phase 24 V AC 1 phase 230 V Fuse code F1U F2U F3U F12B F6B F8B F9B F4U F5U The electrical main power supply should be arranged so that it can be switched on or off independently of the electrical supply to other equipment All PCBs are supplied with a 24 V AC voltage The red led on the main board indicates that power is supplied The table below gives an overview of the fuses for e
129. set points User settings password Screen 1 To enter the password page 2 27 Screen 2 To activate remote control page 2 27 Screen 3 To adjust and activate manual control mode page 2 27 Screen 4 To adjust the thermostat settings page 2 28 Screen 5 To adjust the BMS settings optional page 2 29 Screen6 To define the lead lag mode of both circuits page 2 29 Screen7 To assign password protection to the set point menu page 2 29 Timers direct Screen 1 To read the actual value of the general timers page 2 30 Screen 2 To read the actual value of the compressor timers page 2 30 Screen 3 To read the actual value of the compressor start up timers page 2 30 History direct Screen 1 To read the unit safety information after a shutdown page 2 33 Subscreen To read the high and low pressure of the refrigerant circuit 1 1 1 Subscreen To read the high and low pressure of the refrigerant circuit 2 1 2 Subscreen To read the compressor voltage and current 1 3 Subscreen To read the total running hours of the compressors and the 1 4 capacity steps Screen 2 To read the safety information of circuit 1 after a shutdown page 2 34 Subscreens are identical to the subscreens above Screen 3 To read the safety information of circuit 2 after a shutdown Page 2 35 Subscreens are identical to the subscreens above Info direct Screen 1 To consult the unit information page 2 36 Scree
130. sor thermal protector ID7 S8L S9L flow switch pump contact 2 field wiring J3 ID8 controller bypass optional ID9 10S dual setpoint selection switch field wiring ID10 S6S field wiring remote start stop switch 1D1 S1PH high pressure switch ID2 S14PH high pressure switch J4 1D3 R1P reverse phase protector ID4 K17S overcurrent relay ID5 K3A auxiliary relay for discharge thermal protector C1 NO1 K3M star contactor J5 C2 NO2 K2M delta contactor Part 1 System Outline 1 35 Wiring Layout ESIE98 03 Description PCB s EUWA 80 120K X Wiring diagram Block Connection Description symbol C3 NO3 K1M compressor on C4 NO4 H1P field wiring pump contact and general operation indication C5 NO5 H2P field wiring alarm indication J6 C12 NO12 ESH field wiring evaporator heater il An optional heatertape must be installed refer to Options for EUWA 40 120K on page 1 43 and Options for EUWA 40 120KX on page 1 43 J17 G GO power supply controller ID11 ID11R S5E emergency stop button J21 1D12 1D12R C9 NO9 NC9 K7F fan step 1 contactor J22 C10 NO10 NC10 K8F fan step 2 contactor C11 NO11 NC11 K9F fan step 3 contactor C6 NO6 Y11S 12 capacity step for compressor J24 C8 NO8 Y12S 40 capacity step for compressor C13 NO13 Y13S 70 capacity step for compressor The following table explains the different blocks o
131. ssor indication Part 3 Troubleshooting Overview of Fault Indications and Safeties ESIE98 03 3 14 Part 3 Troubleshooting ESIE98 03 Checking the Inputs and Outputs 3 Checking the Inputs and Outputs 3 1 What Is in This Chapter Introduction In this chapter you will find information on how to measure and check the most important inputs Overview This chapter covers the following topics Topic See page 3 2 Checking the Temperature Sensors page 3 16 3 3 Checking the Digital Inputs and Outputs page 3 18 3 4 Checking the Power Supply and Fuses page 3 19 Part 3 Troubleshooting 3 15 Checking the Inputs and Outputs ESIE98 03 3 2 Checking the Temperature Sensors Introduction Types of sensors How to check If the cause of the problem is related to the temperature sensors then the sensors should be checked prior to changing the PCB or an output device The following types of temperature sensors m sensors connected to the controller PCB R3T R4T R5T For more information about these sensors refer to Main board EUWA 40 120K X on page 1 34 To check the temperature sensors proceed as follows Step Action 1 Disconnect the sensor from the PCB or discharge thermal protector 2 Read the temperature and the resistor value 3 Check if the measured values correspond with the values in the appropriate table
132. ssword amianto e ta a A A i Seek Se ii da tos 2 41 changing Mia a a AA ol A A ah A 3 29 Oli AE AO AAA PESADAS AAA EE A RAE 3 30 refrigerant A e A a da 3 32 charging AM NE A A e de Melatonin ag 3 30 checking digital iNPUTS OUTPUTS ves ia ina AAA ala SoA S T alee Os Ade Md EA glans 3 18 INPUTS OUIPUIS i ec ee ta ed nin ee Leet ated de eee ne ote nals Sede eee 3 15 power Supply ANA FUSOS 000 een eee ak tt id 3 19 TEMPEFALULESEMSOMS iene ria a al bye nny Blanch stun IEA DOM ada is atea 3 16 checks CHSCHI Cal CHECKS i code Tels Sen a rn dl o tE ice dante sede ai sed 4 7 Generali Checks cita elated du A A a Ghar Oh eek oe 4 4 water TOW iia a Ed a A ad weed ba daa AEN 4 5 Water piping CHECKS morir o A A A E Bale ee 4 5 Water Pressure asiani pepe tes ata ia LETS Set An Ae Aa Ae a aa x 45 Water UNITY z niare Ud el Mula ter ea aE e e a aa a aaa senshi Manta attends A a recta ed ihe 4 6 Walter vol m atic ee ac A ne dank ok A ee Nae 4 5 cleaning filt r at A A A dies Me Eee ees een bad we ees eee yaaa ea ey 3 30 compressor general wie A MPa dae tek ee bop Para aa de wale eg 1 26 Start Up SCQueNCes it ne Rot acai ey ane tone Ha See ee Ne eed ane Se A 2 9 MIT TEI E sce scarce hescetee atcha a a rea 2 30 CONOS Onion ri A A taa a 1 26 CONNECIONS raan E con aceite wile ied od AA oe A Anne RARA A da eh EATE ie 1 44 1 45 COMA Ci a A IO TE o Te ati BE AO E N 3 4 3 5 control MAA a A RN 2 6 Ur a Aa AA ia eae 2 6 Index i
133. t indication on the controller display This will help you to find the cause of the problem Overview This chapter covers the following topics Topic See page 2 2 Fault Indication page 3 8 2 3 Safeties Overview page 3 12 Part 3 Troubleshooting 3 7 Overview of Fault Indications and Safeties ESIE98 03 2 2 Fault Indication What happens in case of an alarm The units are equipped with two kinds of safety devices Unit alarm Circuit alarm Function Protects the unit in general Protects the individual circuits Description m all compressors are shut down m the compressor of the m the red LED inside the key lights corresponding circuit is shut down up m the red LED inside the key lights m the buzzer is activated up m the buzzer is activated Action to Press to acknowledge the alarm Press Dto acknowledge the alarm take Display UNIT SAFETY CIRCUIT 1 2 SAFETY example FLOW SUITCH HIGH PRESSURE SWITCH INL BUTL INL BUTL AMB ANB For more information about the safety devices refer to What Happens in Case of an Alarm on What to do in case page 2 20 In case of an alarm proceed as follows of an alarm Step Action Result 1 Press to acknowledge m The buzzer stops theialarm m The O LED starts blinking m A unit or circuit safety is activated If the safety isa
134. t unit disabled register inlet water temperature reset inlet temperature is raised with 1 5 K 1 thermostat step result unit enabled 1 Alarm is on hold and reset goes automatically 2 10 Part 2 Functional Description ESIE98 03 Functional Control General overview The following table shows a general view of freeze up temperatures in case of protection and prevention Minimum outlet water M O W Freeze up protection Freeze up prevention Standard 4 2 5 C 3 C 2 C 0 5 C 1 C 0 C 1 5 C 1 C ZH 5 C 6 5 C 6 C 7 C 8 5 C 8 C ZL 10 C 11 5 C 11 C 12 C 13 5 C 13 C Part 2 Functional Description Functional Control ESIE98 03 1 7 Lead lag Control only for EUWA 80 120K X Description Available modes Lead lag hours in automatic mode Equal start up Lead lag control will determine the circuit start up sequence in case of capacity demand It prevents the unit from always starting up the same circuit The lead lag control is available in 3 modes as explained in the table below Mode Description automatic The controller decides whether circuit 1 or circuit 2 starts up first manual C1 gt C2 Circuit 1 starts up before circuit 2 If circuit 1 is de activated due to a fail ure circuit 2 will start up instead manual C1 lt C2 Circuit 2 starts up before c
135. tal input compressor control circuit m leaving evaporator water temperature from 4 C to 20 C pull down condition to 25 C Part 1 System Outline 1 7 General Outline ESIE98 03 EUWA 40 60KX In the following table you will find the technical specifications of chiller types EUWA 40 60KX Capacity steps Model EUWA 40KX EUWA 50KX EUWA 60KX Nominal cooling Nominal cooling input SIIN 53 7 kW 64 kW 100 75 55 100 75 55 100 75 55 MAIN COMPONENTS Compressor type speed crankcase heater model x n Evaporator type min water volume system water flow rate nom water pressure drop insulation material Condenser type rows x stages x fin pitch face area nominal air flow discharge fan type n of fans n of motors x output nominal speed Piping connections evap water in outlet evaporator water drain relief device outlet Refrigerant circuit refrigerant type refrigerant charge refrigerant control oil type oil charge volume n of circuits semi hermetic single screw 2880 rpm 150 W ZHASLLFLYE ZHASLLFLTE 2 pass 1 circuit shell 8 tube dry expansion ES 185 2400 Min 150 Max 600 l min 13 kPa PVC nitril foam cross fin coil Hi X tubes and chromate coated waffle louvre fins 2 x 50 x 2 0mm 8 4 m2 960 m3 min vertical direct drive propeller 4 4x 500 W 750 rpm flexible joint 114 3 1 2 FPT compressor 1 NPT R 134a 30
136. temperature gt manual software reset S3T bimetal protector THERMAL 135 C when discharge S4T on off PROTECTION 1 2 temperature lt 115 C overcurrent relay OVERCURRENT 1 2 overcurrent 2 m manual hardware K17S bimetal reset K18S on off m manual software reset compressor motor COMPRESSOR compressor motor automatic reset at QM bimetal thermal protector THERMAL PROTEL windings temperature gt 93 C Q2M on off TOR Ve 115 C reverse phase REVERSE PHASE m single phasing correct phase RiP contact DONTCCOTINN 17 5 H protector PROTEL TON 1 0 a imbalance ofmore a than 20 between pomor acron the phases m reversed phases m no power fan motor thermal fan motor windings automatic reset at Q11F bimetal protector temperature gt 160 C 130 C 15K Q14F on off 10K Q21F Q24F 1 The circuit 1 or 2 is not indicated on the single circuit units EUWA 40 60K X 2 An overview of the fuses and overcurrent relays is given in Checking the Power Supply and Fuses on page 3 19 3 12 Part 3 Troubleshooting ESIE98 03 Overview of Fault Indications and Safeties Safety devices The following pictures give a visual view of some of the safety devices high pressure service port high pressure switch 2 high pressure switch 1 discharge safety valve emergency stop power supply covers overcurrent reset star delta configuration connection towards compre
137. thermal protector m Blocked fan m Blocked condenser m State of the fans free rotation m State of the condenser Reverse phase protection Incorrect phase direction One phase missing Swap two phases Connect the loose phase An overview of the fault indications and safeties is given in Overview of Fault Indications and Safeties on page 3 7 Part 3 Troubleshooting 3 23 Troubleshooting ESIE98 03 4 3 Refrigeration circuit repairs Electrical circuit repairs General Repair Procedures The general procedure for refrigeration circuit repairs is explained below Step Action 1 Recover the refrigerant from the unit or perform a pump down depending on the part that needs to be changed Refer to Pump Down on page 3 28 a3 It is strictly forbidden to release refrigerant into the atmosphere during service or repair jobs Make use of a recovery unit Perform the repair according to the normal procedure There are no special procedures for the replacement of refrigeration parts We refer to the general DAIKIN air conditioning service manual for more information on the stand ard practice of refrigeration works Pressurise the system Make sure there are no leaks Charge with the proper amount of refrigerant all relevant European and national regulations A All refrigeration work must be carried out by a licensed r
138. to replace technical know how acquired through training and experience The basic rules of good workmanship still apply but should be more strictly applied on R 134a EUWA 40 120KX applications The asterix in EUWA 40 120K X refers to B M T S or D which are abbreviations for T TuV approval Germany S Swedish approval Sweden M Service des Mines approval France D RLK approval the Netherlands B Standard unit Italian approval Icons are used to attract the attention of the reader to specific information The meaning of each icon is described in the table below Type of ogi Icon Information Description Note A note provides information that is not indispensable but may i nevertheless be valuable to the reader such as tips and tricks Caution A caution is used when there is danger that the reader through A incorrect manipulation may damage equipment loose data get an unexpected result or has to restart part of a procedure Introduction ESIE98 03 Icon Type or E Description information D Warning A warning is used when there is danger of personal injury Reference A reference guides the reader to other places in this binder or in this manual where he she will find additional information on a specific topic vi ESIE98 03 Introduction What is in this part Part 1 System Outline
139. ts vacuum pump and oil recipients for R 134a and polyester oils Ester oil is very hygroscopic This strong affinity for water increases the water content by hundred PPM in a few hours While it is very difficult to remove this humidity by means of a vacuum pump the maximum humidity level is set at 75 PPM after 48 hours operation E The new filter cores on base of ZEORUM are very sensitive to this humidity Therefore a minimum air exposure before installation in the system is a must The maximum contamination of mineral oil in ester oil is 5000 PPM For more information about the handling of R 134a refer to Precautions on page 5 4 4 12 Part 4 Commissioning and Test Run ESIE98 03 Refrigerant R 134a 3 3 Characteristics Characteristic table The following table shows the characteristics for R 134a Description Chemical formula CH2F CF3 Chemical designation 1 1 1 2 terrafluoroethane Molar mass g mol 102 03 Boiling point at 1 013bar C 26 2 Freezing point C 101 Critical temperature C 40 64 Critical pressure abs bar 0 508 Critical density kg l 1 26 Specific heat capacity of the liquid boiling point kJ kg K 215 5 Heat of vaporization boiling point kJ kg 14 9 Surface tension boiling point mN m 1 377 Density of the liquid at boiling point kg l 1 207 Density of the liquid at 25 C kg l 1 093 Isentropic exponent 30 C 1 013bar x
140. um outlet water temperature 4 1 Use _ to select the correct temperature A When you enter a lower temperature 2 Press than 4 C make sure that you adapt the glycol quantity in the water 2 BMS CARD INSTALLED not available N Press 3 LOAD DEFAULTS to change the default settings N Press E To go to the next screen scroll downward using _ and press once Screen 3 This screen shows the running hours of the compressor Line n Display Description Default setting To change the setting 1 RONN HOURS 1 running hours of compressor 1 80800H 1 Use Dand Y to change the digits 2 Press e 2 RONN HOURS 2 running hours of compressor 2 808004 1 Use Dand Y to change the digits only for EUWA 80 120K X 2 Press E To go to the next screen scroll downward using _ and press once A Changing of the running hours is very important when the parts are used as spare parts Screen 4 This screen shows the possibilities of the electrical devices Line n Display Description Default setting To change the setting 1 V A METER V meter A meter optional N 1 Use _ to select yes or no 2 Press O 2 P TRANSA pressure transmitter DANFOSS 1 Use 4_y to select the correct transmitter 2 Press e 3 25 CAPP not available N Do not change default COILS To put the cursor back press Exit of factory menu Press a key different from and O Part 3 Troubleshooting 3 27 Troubleshooting ESIE
141. uzzer stops m The buzzer stops m The LED starts blinking m The LED starts blinking Display UNIT SAFETY CIRCUIT 1 2 SAFETY mpl example LOS HIGH PRESSURE SUITCH 1 INL QUTL INL OTL ANB ANB 1 The safeties that may occur are listed in the table below The unit safeties are The circuit safeties are emergency stop high pressure switches flow switch overcurrent relay freeze up protection discharge thermal protector compressor motor thermal protector reverse phase protector For more information on what to do in case of an alarm refer to page 3 8 2 20 Part 2 Functional Description ESIE98 03 The Digital Controller 2 5 Menu Overview An overview of the menus is given in the table below Menu key Access Screen n Task description See page Read out direct Screen 1 To consult the settings page 2 24 Screen 2 To consult information about the status of the circuits page 2 24 Screen 3 To consult information about the pressures of circuit 1 page 2 24 Screen 4 To consult information about the pressures of circuit 2 page 2 25 Screen 5 To consult the voltage and compressor current optional page 2 25 Screen 6 To consult the ambient temperature and the total running page 2 25 hours of the compressors set points direct or Screen 1 To enter a password page 2 26 password Screen 2 To consult and adjust the inlet and outlet water temperature page 2 26
142. valve Y24S temperature of the compressor by cooling with liquid from the condenser It opens on compressor start and closes on compressor stop i A shortage of refrigerant may trip this discharge temperature safety 10 Unloading Y11S The compressor has 3 unloader solenoid valves on the solenoid valves Y12S top Y13S From the 3 valves on the top the first one is 70 the Y21S middle one is 40 and the last one is 12 The valves Y22S are powered up to go to the unloading condition and only Y23S 1 valve is powered per unloaded condition 11 Liquid line solenoid Y15S This valve shuts off the refrigerant flow when the com valve Y25S pressor stops or in case of a power failure It is used to prevent liquid backflow from the condenser to the evaporator in order to avoid wet start and liquid pumping 12 Low and high B1P The low and high pressure transmitters or sensors are pressure transmit B4P used to gain information in order to perform some con ter B2PB5P trols and also act as safety 13 Head pressure This stop valve is used during pump down and service stop valve work in combination with the liquid line stop valve 1 26 Part 1 System Outline ESIE98 03 Piping Layout Visualising the parts N Part name Code Function 14 Ambient R5T The ambient temperature is measured to control the fans temperature during head pressure control Refer to Fan Speed Con sensor trol after Start up Head
143. y py M SUCTION T STOPVALVE Jmc D OPTIONAL 00 HH O SAFETY VALVES m7 O mx a o EVAPORATOR STRAINER 15S NI Y IVM Lucu ivy LNO Y3LVM Y14S CONDENSER D A CHECKVALVE amp FLARE CONN screw conn JE FLANGECONN X PINCHED PIPE gt SPINNED PIPE 1 24 Part 1 System Outline ESIE98 03 Piping Layout Functional diagram The figure below displays the functional diagram of the refrigeration circuit of the chiller types EUWA 80 120KX EUWA 80 120KX ne a O E Y21S i Y22S 10 EVAPORATOR SUCTION STOPVALVE As CHECK VALVE FLARE CONN ae SCREW CONN JE FLANGE CONN X PINCHED PIPE SPINNED PIPE Part 1 System Outline 1 25 Piping Layout ESIE98 03 2 3 Parts Table of the Refrigeration Circuit Parts table The numbers in the table below refer to the numbers in the piping diagrams on the previous pages N

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